Absorbent article with absorbent core structure perimeter seal arrangements

ABSTRACT

A disposable absorbent article having a topsheet, a backsheet, and an absorbent core structure therebetween. The absorbent core structure having an upper nonwoven layer, a lower nonwoven layer, and a portion of an inner core layer disposed therebetween. The portion of the inner core layer is contained within the upper and lower nonwoven layers by sealing a portion of the first and second side regions of the upper nonwoven layer with a portion of the first and second side regions of the lower nonwoven layer at a lateral perimeter seal. An adhesive is positioned between the upper and nonwoven layers in the perimeter seal. The lateral perimeter seal is positioned in the middle region and has a longitudinal seal length that is from about 45% to about 90% of the longitudinal inner core length.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.63/345,582, filed May 25, 2022, and U.S. Provisional Application No.63/413,634, filed Oct. 6, 2022, and U.S. Provisional Application No.63/480,335, filed Jan. 18, 2023, the entire disclosures of which arefully incorporated by reference herein.

FIELD OF THE INVENTION

The present disclosure relates to absorbent articles, and moreparticularly, to absorbent articles with absorbent core structureperimeter seal arrangements that seal a portion of the inner core layeryet still sufficiently contains the liquid absorbent material andmaintains the conforming features of the absorbent articles.

BACKGROUND OF THE INVENTION

Absorbent articles are widely used among consumers, e.g., diapers,training pants, feminine pads, adult incontinence pads, etc. Generally,absorbent articles such as these comprise a topsheet and a backsheet,with an absorbent core structure disposed therebetween. Historically,absorbent core structures for menstrual pad applications utilizecellulose fibers in various ways to manage the complex and variedrheological properties of menstrual fluid and vaginal discharge.

The first approach included cellulose (also known as “fluff” or “pulp”)based thick absorbent cores that can be stiff, bulky, and suffer fromstructural collapse due to the short fiber lengths of cellulose (<2.5mm), particularly when loaded with fluid due to cellulose fibersoftening when wet. Over time, these thick cellulose rich absorbentcores have been made thinner with the inclusion of absorbent polymermaterials, such as absorbent gelling material (“AGM”), to further boosttheir absorption properties. However, these absorbent core structuresare less mechanically strong and even less able to retain their shape,particularly when loaded with liquid exudate. These absorbent corestructures can form cracks and tears while in-use and bunch (a permanentdeformed shape). These thinner structures tend to be even more densified(thus stiffer) and are often wrapped in a simple cellulose tissue orthin nonwoven layer to keep the AGM inside and reduce core tearing andundesirable bunching while in use.

Other approaches combine these wrapped cellulose and AGM cores with anadditional fluid acquisition-distribution layer (above the fluid storagecore) to further improve the performance of these simple wrapped cores.This additional acquisition-distribution layer further serves to improveintegrity and to some degree tearing and bunching of the wrapped core.These acquisition-distribution layers, however, are not ideal forcomplex viscous fluids which need to move over the boundary betweenthese layers. To better facilitate fluid partitioning from theacquisition-distribution system to the fluid storage wrapped celluloseand AGM core, the core can be densified to increase capillarity and theability to pull fluid effectively from the acquisition-distributionlayer above. However, densifying this absorbent system comes at the costof comfort (stiffness) and the ability of the absorbent core structureand/or absorbent article to readily conform to the wearer's uniqueanatomical geometry.

Another material used in absorbent core structure includes an airlaidcore. Airlaid cores are typically composed of cellulose, AGM, andsynthetic binder fibers to enhance wet integrity and often a surfacecoating of a polymer (such as latex) to reduce dust during productmanufacture. Because these materials are manufactured at a separatesupplier offline and need to be transported and introduced into afast-moving production line, they are highly densified and stiff. Thedensification and synthetic binder fibers provide a higher wet integrityin-use and can help facilitate fluid transport from theacquisition-distribution layer to the airlaid core due to highercapillarity. However, this again can be at the cost of comfort(stiffness) and the ability to readily conform to the wearer's uniqueanatomical geometry due to high bending stiffness.

It is known that absorbent core structures which are shaped to follow(fit within) the user's underwear and inner thigh dimensions may help toprovide a comfortable fit that can conform to the body and protect fromleaks. Absorbent articles that are centrally narrow while being wider atthe front and/or back regions may offer the best combination of comfortand protection. However, the narrow, central portion of these absorbentcore structures experience the highest mechanical stress between thethighs during wear. As such, it is difficult to maintain the integrityand resiliency of the absorbent core structure and/or absorbent articlein this region. If absorbent materials escape from or shift within theabsorbent core structure, the absorbent article may become uncomfortableto wear and may not provide effective fluid handling. Current absorbentarticles generally have a full perimeter seal surrounding the absorbentmaterial in order to maintain product integrity and avoid bunchingissues. One method of creating such a full perimeter seal is to sandwichthe absorbent material between materials which have a substantiallygreater width than the entire absorbent material and then to cut thematerial out to follow the shape of the absorbent material. Thisrequires more materials and/or additional manufacturing steps whichincreases the cost and complexity of manufacturing and may result inincreased waste as excess materials are trimmed during manufacturing.

There is a need for improved absorbent articles that provide acomfortable, conformable fit that requires less materials and that canbe made without undesirable cost and complexity while still deliveringsufficient resiliency and fluid handling.

SUMMARY OF THE INVENTION

The present disclosure solves the problem of the complex and costlymanufacturing of absorbent articles with conforming features. Theabsorbent articles of the present disclosure comprise upper and lowernonwoven layers that sandwich an inner core layer comprising a liquidabsorbent material. A portion of the inner core layer in the middleregion of the absorbent core structure and/or absorbent article iscontained within the upper and lower nonwoven layers by sealing aportion of the upper and lower nonwoven layer side regions to define alateral perimeter seal where adhesive is positioned between the uppernonwoven layer with the lower nonwoven layer and bonds the layerstogether. This lateral perimeter seal enables the use of narrow upperand/or lower nonwoven layers to partially seal the inner core layer withless material usage and enables a simpler manufacturing process andprovides an economic benefit.

A disposable absorbent article comprises a front end region, a middleregion, and a back end region; a topsheet; a backsheet; and an absorbentcore structure disposed between the topsheet and backsheet. Theabsorbent core structure comprises (a) an upper nonwoven layercomprising polymer fibers and having a basis weight of from about 30 gsmto about 65 gsm; wherein the upper nonwoven layer comprises a first sideregion, a laterally opposing second side region, and a first nonwovenlateral width; (b) a lower nonwoven layer comprising polymer fibers andhaving a basis weight of from about 10 gsm to about 40 gsm; wherein thelower nonwoven layer comprises a first side region, a laterally opposingsecond side region, and a nonwoven second lateral width; and (c) aninner core layer having a longitudinal inner core length, a first innercore layer lateral width, and a second inner core lateral width. Aportion of the inner core layer is disposed between the upper nonwovenlayer and the lower nonwoven layer. The inner core layer comprises aliquid absorbent material comprising from about 50% to about 85%cellulosic fibers, by weight of the inner core layer, and from about 15%to about 50% superabsorbent particles, by weight of the inner corelayer. The absorbent core structure has an average density of betweenabout 0.045 g/cm3 and about 0.15 g/cm3. The portion of the inner corelayer is contained within the upper nonwoven layer and the lowernonwoven layer by sealing a portion of the first side region and thesecond side region of the upper nonwoven layer with a portion of thefirst side region and the second side region of the lower nonwoven layerat a lateral perimeter seal, wherein an adhesive is positioned betweenthe upper nonwoven layer and the lower nonwoven layer in the perimeterseal. The lateral perimeter seal is positioned in the middle region andhas a longitudinal seal length that is from about 45% to about 90% ofthe longitudinal inner core length.

A disposable absorbent article comprises a front end region, a middleregion, and a back end region; a topsheet; a backsheet; and an absorbentcore structure disposed between the topsheet and backsheet. Theabsorbent core structure comprises (a) an upper nonwoven layercomprising polymer fibers and having a basis weight of from about 30 gsmto about 65 gsm; wherein the upper nonwoven layer comprises a first sideregion and a laterally opposing second side region; (b) a lower nonwovenlayer comprising polymer fibers and having a basis weight of from about10 gsm to about 40 gsm; wherein the lower nonwoven layer comprises afirst side region and a laterally opposing second side region; (c) aninner core layer comprising a first side edge and a laterally opposingsecond side edge and having a longitudinal inner core length; whereinthe inner core layer is positioned between the upper nonwoven layer andthe lower nonwoven layer; and (d) an adhesive zone disposed intermediatea portion of at least one of the upper nonwoven layer and the lowernonwoven layer and the inner core layer. The inner core layer comprisesa liquid absorbent material comprising a cellulosic fiber and asuperabsorbent particle, and wherein the absorbent core structure has anaverage density of between about 0.045 g/cm3 and about 0.15 g/cm3. Theupper nonwoven layer and the lower nonwoven layer substantiallysurrounds the adhesive zone and the inner core layer. A portion of theadhesive zone extends laterally outboard of the first and second sideedges of the inner core layer and bonds the upper nonwoven layer to thelower nonwoven layer at a lateral perimeter seal. A portion of the innercore layer extends laterally outboard of the adhesive zone to define anunsealed portion; wherein the unsealed portion is positionedlongitudinally outboard of the lateral perimeter seal.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a representation of an absorbent core structurein accordance with the present disclosure with the wearer facing surfaceoriented toward the viewer.

FIG. 2 is a cross section of the absorbent core structure.

FIG. 3 is a plan view of an absorbent article with the wearer facingsurface oriented toward the viewer showing a first configuration of theabsorbent core structure.

FIG. 3A is a plan view of an absorbent article with the wearer facingsurface oriented toward the viewer showing a second configuration of theabsorbent core structure.

FIG. 3B is a plan view of an absorbent article with the wearer facingsurface oriented toward the viewer showing a third configuration of theabsorbent core structure.

FIG. 3C is a plan view of an absorbent article with the wearer facingsurface oriented toward the viewer showing a fourth configuration of theabsorbent core structure.

FIG. 4A is a cross-sectional view of the absorbent article of FIG. 3taken along line 4A-4A.

FIG. 4B is a cross-sectional view of the absorbent article of FIG. 3taken along line 4B-4B.

FIG. 5 is a cross-sectional view of the absorbent article of FIG. 3taken along line 5-5.

FIG. 6 is a plan view of an absorbent article showing a configuration ofan inner core layer and an adhesive zone.

FIG. 7 is a plan view of a representation of an absorbent article inaccordance with the present disclosure with the wearer facing surfaceoriented toward the viewer showing flex bond channel regions andstructural bond sites.

FIG. 8 is a close up illustration of a structural bond site inaccordance with the present disclosure.

FIG. 9 is a cross-sectional of the structural bond site of FIG. 4 .

FIGS. 10A-C are a test method arrangement for the Wet and Dry CD UltraSensitive 3 Point Bending Method.

FIGS. 11, 12A and 12B are the test method arrangement for the Wet andDry Bunched Compression Test.

FIGS. 13A and 13B are illustrative graphs of Bunch Curves resulting fromthe Wet and Dry Bunched Compression Test. The graphs in FIGS. 13A and13B are shown to illustrate how the calculations in the method may beperformed and do not represent the data described herein.

DETAILED DESCRIPTION OF THE INVENTION

As used herein “disposable absorbent article” or “absorbent article”shall be used in reference to articles such as diapers, training pants,diaper pants, refastenable pants, adult incontinence pads, adultincontinence pants, feminine hygiene pads, cleaning pads, and the like,each of which are intended to be discarded after use.

As used herein “absorbent core structure” shall be used in reference tothe upper nonwoven layer, the lower nonwoven layer, and the inner corelayer disposed between the upper nonwoven layer and the lower nonwovenlayer.

As used herein “hydrophilic” and “hydrophobic” have meanings as wellestablished in the art with respect to the contact angle of water on thesurface of a material. Thus, a material having a water contact angle ofgreater than about 90 degrees is considered hydrophobic, and a materialhaving a water contact angle of less than about 90 degrees is consideredhydrophilic. Compositions which are hydrophobic, will increase thecontact angle of water on the surface of a material while compositionswhich are hydrophilic will decrease the contact angle of water on thesurface of a material. Notwithstanding the foregoing, reference torelative hydrophobicity or hydrophilicity between a material and acomposition, between two materials, and/or between two compositions,does not imply that the materials or compositions are hydrophobic orhydrophilic. For example, a composition may be more hydrophobic than amaterial. In such a case neither the composition nor the material may behydrophobic; however, the contact angle exhibited by the composition isgreater than that of the material. As another example, a composition maybe more hydrophilic than a material. In such a case, neither thecomposition nor the material may be hydrophilic; however, the contactangle exhibited by the composition may be less than that exhibited bythe material.

As used herein, the term “filament” refers to any type of continuousstrand produced through a spinning process, a meltblowing process, amelt fibrillation or film fibrillation process, or an electrospinningproduction process, or any other suitable process to make filaments. Theterm “continuous” within the context of filaments are distinguishablefrom staple length fibers in that staple length fibers are cut to aspecific target length. In contrast, “continuous filaments” are not cutto a predetermined length, instead, they can break at random lengths butare usually much longer than staple length fibers.

As used herein, “machine direction” refers to the direction in which aweb flows through an absorbent article converting process. For the sakeof brevity, may be referred to as “MD”.

As used herein, “cross machine direction” refers to the direction whichis perpendicular to the MD. For the sake of brevity, may be referred toas “CD”.

As used herein, “resilient” refers to a material that tends to retainits shape both in the dry and wet states and when subjected to acompression force tends to recover its original, pre-compression shapewhen such force is removed. In some aspects, the upper and/or lowernonwoven layers described herein may be resilient.

As used herein, “wearer-facing” (sometimes referred to herein asbody-facing) and “outward-facing” (sometimes referred to herein asgarment-facing) refer respectively to the relative location of anelement or a surface of an element or group of elements. “Wearer-facing”implies the element or surface is nearer to the wearer during wear thansome other element or surface. “Outward-facing” implies the element orsurface is more remote from the wearer during wear than some otherelement or surface (i.e., element or surface is proximate to thewearer's garments that may be worn over the absorbent article).

“Inboard,” with respect to a first feature of an article and itsposition relative a second feature or location on the article, meansthat the first feature lies closer to a respective axis of the articlethan the second feature or location, along a horizontal x-y planeapproximately occupied by the article when laid out flat, extended tothe full longitudinal and lateral dimensions of its component webmaterials against any contraction induced by any included pre-strainedelastomeric material, on a horizontal surface. Laterally inboard meansthe first feature is closer to the longitudinal axis, and longitudinallyinboard means the first feature is closer to the lateral axis.Conversely, “outboard,” with respect to a first feature of an articleand its position relative a second feature or location on the article,means that the first feature lies farther from the respective axis ofthe article than the second feature or location.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

The disposable absorbent articles described herein comprise a topsheet,a backsheet, and an absorbent core structure which comprises an uppernonwoven layer, a lower nonwoven layer, and an inner core layerpositioned intermediate the upper and lower nonwoven layers. A portionof the inner core layer in the middle region of the absorbent corestructure and/or absorbent article is contained within the upper andlower nonwoven layers by sealing a portion of the upper and lowernonwoven layer side regions to define a lateral perimeter seal whereadhesive is positioned between the upper nonwoven layer with the lowernonwoven layer and bond the layers together.

In some configurations, the disposable absorbent article may comprisethe following structure (from a wearer-facing surface to anoutward-facing surface): a topsheet, an upper nonwoven layer, an innercore layer, a lower nonwoven layer, and a backsheet. In some aspects,the topsheet may be in direct contact with the upper nonwoven layer, theupper nonwoven layer may be in direct contact with the inner core layer,and/or the inner core layer may be in direct contact with the lowernonwoven layer. By “direct contact”, it is meant that there is nofurther intermediate component layer between the respective layer indirect contact thereto. It is however not excluded that an adhesivematerial may be disposed between at least a portion of the layersdescribed above.

Referring to FIGS. 1 and 2 , absorbent core structure 10 may comprise anupper nonwoven layer 210 and a lower nonwoven layer 220 (also referredto herein collectively as upper and lower nonwoven layers or upper andlower nonwovens) and an inner core layer 200 positioned intermediate theupper nonwoven layer 210 and the lower nonwoven layer 220. The innercore layer 200 may comprise a liquid absorbent material. Without beinglimited by theory, it is believed that the absorbent core structure 10may recover its shape dry or wet across a range of bodily movements andcompressions. The liquid absorbent material may comprise a matrixcomprising cellulosic fibers and superabsorbent particles, sometimesreferred to herein as “fluff/AGM”. The upper and lower nonwoven layers210, 220 may be joined together at a perimeter seal 230 with glue orother conventional bonding methods including, but not limited to,ultrasonic bonding, fusion bonding, crimping, and combinations thereof.

The flexibility and/or resiliency of the absorbent core structureresults in an absorbent article that comfortably conforms to thewearer's anatomical geometry while efficiently managing the fluid as itexits the body. This can, unexpectedly, be achieved without typicaldensification stiffening (for wet integrity) by leveraging resilientupper and lower nonwoven layers composed of resilient polymers locatedabove and below the loosely packed fluff/AGM matrix of the inner corelayer. This absorbent core structure is able to carry the structuralload and recover shape without physically being stiff or losing thedesired structural properties when the absorbent core structure becomeswet.

It is believed that wet integrity/shape stability in a cellulose richabsorbent core structure without substantial densification andstiffening results when select resilient upper and lower nonwovens arepositioned above and below the fluff/AGM matrix of the inner core layerand joined to and around the fluff/AGM matrix. The upper and lowernonwovens require sufficient recovery force to carry the fluff/AGMmatrix back to the original state or a stable fiber orientation statefollowing compression. Wrapping or encapsulating a cellulose rich fluffcore with a simple cellulose tissue or less resilient nonwoven materialmay not exhibit sufficient recovery energy to recover shape in-use andparticularly when wetted. Structural, wet resilient nonwovens detailedherein may exhibit recovery energies following compression that aresufficient to recover the cellulose rich fiber matrix and are chosen todeliver high compression recovery, with relatively low stiffness, inboth dry and wet states.

It was surprisingly found that an absorbent core structure could becreated without the need for a full perimeter seal surrounding the innercore layer. In particular, it was found that by using substantiallystraight-sided upper and/or lower nonwoven layers, material usage andwaste may be reduced as compared to nonwoven layers that are cut outfrom a wider web into a shape that follows the inner core layer shape.It was surprisingly found that nonwoven layers which are wider than atleast the narrowest, central inner core layer width allows for thecreation of a lateral perimeter seal in the middle region (thatcorresponds to the region that experiences the highest mechanical stressduring use) that can effectively contain the liquid absorbent materialof the inner core layer and preserve the integrity and fit of theabsorbent article. As a result, portions of the inner core layer in thefront region and/or back region (which are subject to less mechanicalstress) may be left unsealed by a perimeter seal without significantlyimpacting product integrity, resiliency, and/or performance.

Referring to FIGS. 3-5 , absorbent article 20 may comprise a wearerfacing surface 112, and a garment facing surface 132 and chassis 100.The chassis 100 may include a topsheet 110 and a backsheet 130.Absorbent core structure 10 may be disposed between topsheet 110 andbacksheet 130. Absorbent article 20 and absorbent core structure 10 eachinclude a front region 21, a back region 23, and a middle region 22disposed intermediate the front region and the back region. Aspreviously discussed, absorbent core structure 10 may comprise uppernonwoven layer 210 and lower nonwoven layer 220. The upper nonwovenlayer 210 extends longitudinally between a front edge 403 and a backedge 404 and defines a first side region 400 and a laterally opposingsecond side region 402. Lower nonwoven layer 220 extends longitudinallybetween a front edge 408 and a back edge 409 and defines a first sideregion 406 and a laterally opposing second side region 407.

The upper nonwoven layer 210 may have a first nonwoven lateral widthWN1, and the lower nonwoven layer 220 may have a second nonwoven lateralwidth WN2. In some configurations, the first and second nonwoven lateralwidths WN1,WN2 may be substantially the same. In some configurations,the first and second nonwoven lateral width WN1, WN2 may be different.The first nonwoven lateral width WN1 and/or the second nonwoven lateralwidth WN2 may be from about 40 mm to about 110 mm, or from 45 mm toabout 90 mm, or from about 50 mm to about 80 mm. The upper and/or lowernonwoven layers 210, 220 may have a longitudinal length of from about100 mm to about 450 mm, or from about 150 mm to about 375 mm. In someconfigurations, the upper and/or lower nonwoven layers 210, 220 mayextend from the front article edge 30 to the back article edge 32. Insome configurations, the upper and/or lower nonwoven layers 210, 220 maynot extend from the front article edge 30 to the back article edge 32.In some configurations, the upper and/or lower nonwoven layers 210, 220may have a longitudinal length that is less than a longitudinal innercore length, LC.

The upper and lower nonwoven layers 210, 220 may be generallyrectangular, however, in some configurations, the upper and lowernonwoven layers 210, 220 may be shaped, meaning that it isnon-rectangular. In some configurations, the upper nonwoven layers 210may be shaped and the lower nonwoven layer 220 may be rectangular, orvice versa. In some configurations, the upper and/or lower nonwovenlayers 210, 220 may have a shaped front and/or back region while themiddle region may be substantially straight.

At least a portion of the inner core layer 200 may be disposed betweenthe upper nonwoven layer 210 and the lower nonwoven layer 210. In someconfigurations, the entire inner core layer 200 may be disposed betweenthe upper nonwoven layer 210 and the lower nonwoven layer 220. The innercore layer 200 extends longitudinally between an inner core layer frontedge 424 and an inner core layer back edge 426 and extends laterallyfrom a first side edge 250 and to a second side edge 252. In someconfigurations, the inner core layer 200 may be shaped. As shown in FIG.6 , the inner core layer 200 may define a first inner core layer lateralwidth, WC1, a second inner core layer lateral width, WC2, and a thirdinner core layer lateral width, WC3, disposed therebetween. In someconfigurations, the first inner core layer lateral width, WC1, may be inthe front region 21 and the second inner core layer lateral width, WC2,may be positioned in the back region 23. In some configurations, thethird inner core layer lateral width, WC3, may be less than the firstand second inner core layer lateral widths, WC1, WC2. In someconfigurations, the second inner core layer lateral width, WC2, may begreater than the first and third inner core layer lateral width, WC1,WC3. The first inner core layer lateral width, WC1, may be from about 50to about 80 mm, the second inner core layer lateral width, WC2, may befrom about 55 mm to about 100 mm, the third inner core layer lateralwidth, WC3, may be from about 40 mm to about 70 mm. In someconfigurations, the inner core layer 200 may be shaped to conform to awearer's inner thigh geometry, such as, for example, an hourglass shape,an offset hourglass shape (one end is wider than an opposite end and anarrowed mid-section between the ends), a bicycle seat shape (one endand central portion are narrower than the second end), an oval, or atrapezoid shape. While a shaped inner core layer may be preferred, insome configurations, the inner core layer may be rectangular.

An adhesive zone 525 may be disposed intermediate at least one of theupper nonwoven layer 210 and the lower nonwoven layer 220 and the innercore layer 200. The adhesive zone 525 may comprise an adhesive 528 thatextends from the first side region 400 of the upper nonwoven layer 210to the second side region 402 of the upper nonwoven layer 210 and/orfrom the first side region 406 of the lower nonwoven layer 220 to thesecond side region 407 of the lower nonwoven layer 220. As shown in FIG.6 , the adhesive zone 525 may extend from a first edge 525 a to a secondedge 525 b to define an adhesive zone lateral width, WZ, of from about35 mm to about 110 mm, or from about 40 to about 105 mm. In someconfigurations, the first and second edge 525 a, 525 b of the adhesivezone 525 may be coterminous with or spaced laterally inboard from thelateral edges of the upper and/or lower nonwoven layers 210, 220. Insome configurations, as shown in FIG. 3 , gap regions 530 may be definedon the upper and/or lower nonwoven layers 210, 220 by the absence ofadhesive 528 between the first and second edges 525 a, 525 b of theadhesive zone 525 and the edge of the nonwoven. The gap region 530 mayhave a width of less than 5 mm, or from about 0.1 mm to about 5 mm, orfrom about 0.5 to about 3 mm. In some configurations, the upper nonwovenlayer 210 and the lower nonwoven layer 220 may substantially surroundthe adhesive zone 525 and the inner core layer 200.

In some configurations, a portion of the inner core layer 200 may becontained within the upper nonwoven layer 210 and the lower nonwovenlayer 220 by sealing a portion of the first side region 400 and thesecond side region 402 of the upper nonwoven layer 210 with a portion ofthe first side region 406 and the second side region 407 of the lowernonwoven layer 220 to define a lateral perimeter seal 230 where adhesive528 is positioned between the upper nonwoven layer 210 and the lowernonwoven layer 220. As such, adhesive 528 may bond the upper nonwovenlayer 210 with the lower nonwoven layer 220. The lateral perimeter seal230 may be positioned in the middle region 22 and may have alongitudinal seal length, LS, that is from about 45% to about 90% of alongitudinal inner core length, LC, or from about 50% to about 85%.Lateral perimeter seal 230 may have a maximum seal width, WS, of fromabout 1 mm to about 15 mm, or from about 2 mm to about 10 mm, or fromabout 3 mm to about 8 mm.

Without being limited by theory, it is believed that upper and lowernonwoven layers comprising polymer fibers may hold their shape andresist plasticizing when wet when at least partially attached to theliquid absorbent material via a core construction adhesive (appliedeither directly to the liquid absorbent material or the nonwoven) chosento achieve a bond but not disrupt the flow of fluid into the liquidabsorbent material. It was further found that a lateral perimeter sealhaving a longitudinal seal length LS of from about 45% to about 90% ofthe longitudinal inner core length LC and being positioned in the middleregion is able to sufficiently contain the liquid absorbent material ofthe inner core layer during manufacturing and in use and allows theupper and lower nonwoven layers to maintain structural function duringphysical deformation between the wearer's thighs without separating.This may provide for more efficient manufacturing processes bysubstantially avoiding contamination of manufacturing lines with liquidabsorbent material that may escape from the inner core during processingand may limit potential product integrity or bunching issues during use.In addition, creating a lateral perimeter seal may enable an absorbentcore structure to be shaped to conform to inner thigh geometry and toreduce the cost of manufacturing by using less materials, using lesscomplex manufacturing steps, and creating less waste.

With continued reference to FIG. 3 , a portion of the inner core layer200 may extend laterally outboard of the adhesive zone 525 to define anunsealed portion 420. The unsealed portion 420 may be positionedlongitudinally outboard of the lateral perimeter seal 230. It is to beappreciated that the absorbent core structure 10 may comprise one ormore unsealed portions 420, such as for example, two, three, or fourunsealed portions, depending on the size and/or positioning of the upperand lower nonwoven layers in relation to the size and/or positioning ofthe adhesive zone and the inner core layer.

The absorbent core structure 10 may comprise a first unsealed portion423 a where a portion of the inner core layer 200 extends laterallyoutboard of the adhesive zone 525. In some configurations, the absorbentcore structure 10 may comprise a second unsealed portion 423 b where asecond portion of the inner core layer 200 extends laterally outboard ofthe adhesive zone 525. Second unsealed portion 423 b may be laterallyseparated from first unsealed portion 423 a by a sealed portion 410. Insome configurations, the first and second unsealed portions 423 a, 423 bmay be positioned in the back region 23 and may extend longitudinallyinto a portion of the middle region 22. The absorbent core structure 10may further comprise a third unsealed portion 421 a where a thirdportion of the inner core layer 200 extends laterally outboard of theadhesive zone 525. In some configurations, the absorbent core structure10 may comprise a fourth unsealed portion 421 b where a fourth portionof the inner core layer 200 extends laterally outboard of the adhesivezone 525. Fourth unsealed portion 421 b may be laterally separated fromthird unsealed portion 421 a by a sealed portion 410. In someconfigurations, the third and fourth unsealed portions 421 a, 421 b maybe positioned in the front region 21 and may extend longitudinally intothe middle region 22. It is to be understood that an unsealed portion420 may also be formed in configurations wherein a portion of the innercore layer perimeter 200 a is coterminous with a first or second edge525 a, 525 b of the adhesive zone 525, such as shown for example in FIG.3A.

The first and second unsealed portions 423 a, 423 b may have an unsealedlongitudinal length L1U that is about 5% to about 30%, or from about 8%to about 25%, of the longitudinal inner core length, LC. The third andfourth unsealed portions 421 a, 421 b may have an unsealed longitudinallength L2U that is about 5% to about 30%, or from about 8% to about 25%,of the longitudinal inner core length, LC. In some configurations, theunsealed longitudinal length L1U of the first or second unsealedportions 423 a, 423 b may be greater than the unsealed longitudinallength L2U of the third or fourth unsealed portions 421 a, 421 b.

FIGS. 4A and 4B are cross-sectional views of the absorbent article 20 ofFIG. 3 showing configurations of the absorbent core structure 10. Inparticular, FIG. 4A is a cross-sectional view through the middle region22 of the absorbent article 20 showing upper and lower nonwoven layers210, 220 extend laterally outboard of the first and second side edges250, 252 of inner core layer 200. As discussed above, a portion of theinner core layer 200 may be contained within the upper nonwoven layer210 and the lower nonwoven layer 220 by sealing a portion of the firstside region 400 and the second side region 402 of the upper nonwovenlayer 210 with a portion of the first side region 406 and the secondside region 407 of the lower nonwoven layer 220 to define lateralperimeter seal 230. FIG. 4B is a cross-sectional view through the backregion 23 of the absorbent article 20 showing upper and lower nonwovenlayers 210, 220 extend laterally outboard of the first and second sideedges 250, 252 of inner core layer 200. As discussed above, a portion ofthe inner core layer 200 may extend laterally outboard of the adhesivezone 525 (not shown) to define unsealed portion 420. It is to beappreciated that the garment facing surface of the upper nonwoven layer210 and/or the wearer facing surface of the lower nonwoven layer 220 maybe coated with adhesive 528 to provide a connection with the inner corelayer 200 and/or to form perimeter seal 230. Adhesive between the layers(except for in the perimeter seal) is not shown in FIGS. 4A and 4B forsimplicity.

Referring to FIGS. 3-3C, the upper and lower nonwoven layers 210, 200may be further joined at a front perimeter seal region 430 and/or a backperimeter seal region 432 positioned longitudinally outboard of theinner core layer 200. FIG. 5 is a cross-sectional view taken along line5-5 of FIG. 3 showing front the perimeter seal region 430 and the backperimeter seal region 432. The front perimeter seal region 430 and/orthe back perimeter seal region 432 may extend longitudinally from aninner core layer perimeter 200 a a distance of from about 3 mm to about30 mm, or from about 5 mm to about 15 mm Without being limited bytheory, it is believed that front and/or back perimeter seal regions430, 432 of less than about 3 mm may not provide a sufficient distanceon the manufacturing line to avoid contamination of liquid absorbentmaterial outside of the inner core layer. In some configurations, thefront perimeter seal region 430 may be coterminous with or spacedlongitudinally inboard from the front edge 403 of the upper nonwovenlayer 210 and/or the front edge 406 of the lower nonwoven layer 220. Insome configurations, the back perimeter seal 432 may be coterminous withor spaced longitudinally inboard from the back edge 404 of the uppernonwoven layer 210 and/or the back edge 409 of the lower nonwoven layer220.

As discussed herein and as illustrated in the accompanying figures, theabsorbent core structure 10 may comprise different configurations withrespect to sealing the inner core layer within the upper and lowernonwoven layers. FIGS. 3A-3C are plan views of an absorbent article withthe wearer facing surface oriented toward the viewer showing additionalconfigurations of the absorbent core structure. As shown in FIG. 3A, thefirst inner core layer lateral width WC1 and the adhesive zone width WZmay be substantially the same, creating an unsealed portion 420 whereadhesive 528 does not extend laterally outboard of the inner core layerperimeter 200 a and the upper nonwoven layer 210 is not joined to thelower nonwoven layer 220 in this region. It is to be understood that insome configurations the second inner core layer lateral width WC2 may besubstantially the same as the adhesive zone width WZ, thus defining anunsealed portion in the back region 23. As shown in FIG. 3B, the firstinner core layer lateral width WC1 may be less than the adhesive zonewidth WZ. Upper and lower nonwoven layers 210, 220 and adhesive zone 525may substantially surround the inner core layer in the front region, andlateral perimeter seal 230 may extend longitudinally from the middleregion 22 into the front region 21. In this configuration, the innercore layer is sealed within the upper and lower nonwoven layers 210, 220in the middle region 22 and the front region 21. It is to be understoodthat in some configurations the second inner core layer lateral widthWC2 may be less than the adhesive zone width WZ, thus creating a lateralperimeter seal 230 that extends longitudinally from the middle region 22to the back region 23.

As shown in FIG. 3C, at least one of the upper nonwoven layer 210 andthe lower nonwoven layer 220 may be narrower than at least a portion ofthe inner core layer. In some configurations, the upper nonwoven layer210 and/or lower nonwoven layer 220 may be narrower than the first innercore layer lateral width, WC1, and/or the second inner core layerlateral width, WC2. In this configuration, a portion of inner core layer200 may be disposed between the upper nonwoven layer 210 and the lowernonwoven layer 220. A portion of the inner core layer may be containedwithin the upper nonwoven layer 210 and the lower nonwoven layer 220 bysealing a portion of the first side region 400 and second side region402 of the upper nonwoven layer 210 with a portion of the first sideregion 406 and the second side region 407 of the lower nonwoven layer220 at a lateral perimeter seal 230. The second inner core lateral widthWC2 may be greater than the first nonwoven lateral width WN1 of theupper nonwoven layer 210 and/or the second nonwoven lateral width WN2 ofthe lower nonwoven layer 220. In this configuration, a portion of theinner core layer may extend laterally outboard of at least one of theupper and lower nonwoven layers and adhesive zone 525 to define anunsealed portion 420 in the back region 23. It is to be appreciatedthat, in some configurations, the first inner core lateral width WC1 maybe greater than the first nonwoven lateral width WN1 of the uppernonwoven layer 210 and/or the second nonwoven lateral width WN2 of thelower nonwoven layer 220. In this configuration, a portion of the innercore layer may extend laterally outboard of at least one of the upperand lower nonwoven layers and adhesive zone 525 to define an unsealedportion 420 in the front region 21. In some configurations, adhesive 528may extend to the lateral edges of the upper and/or lower nonwovenlayers 210, 220, with substantially no gap region present.

Referring to FIGS. 3-3C and FIG. 5 , the front edge 403 of the uppernonwoven layer 210 and/or the front edge 408 of the lower nonwoven layer220 may be coterminous with or spaced longitudinally inboard from afront article edge 30. In some configurations, the back edge 404 of theupper nonwoven layer 210 and/or the back edge 409 of the lower nonwovenlayer 220 may be coterminous with or spaced longitudinally inboard froma back article edge 32. The absorbent article 20 may further comprisecrimp seal 500 positioned in the front region 21 and/or the back region23. In some configurations, the crimp seal 500 may extend from the frontregion 21 and/or the back region 23 into the middle region 22. In someconfigurations, crimp seal 500 may be positioned longitudinally outboardof the front and back perimeter seals 430, 432. In some configurations,front and/or back perimeter seal regions 430, 432 may extend into crimpseal 500. Crimp seal 500 may join the topsheet 110, the backsheet 130,and at least one of the upper nonwoven layer 210 and the lower nonwovenlayer 220. In some configurations, crimp seal 500 may join topsheet 110to backsheet 130. It was surprisingly found that crimp seal 500 mayinclude upper and/or lower nonwoven layers 210, 220 without becomingstiff and uncomfortable. The crimp seal 500 may be substantially free ofliquid absorbent material.

While the figures show the upper and lower nonwoven layers 210, 220extending to the front and back article edges 30, 32, it is to beappreciated that the front and/or back edges of the upper and/or lowernonwoven layers may be positioned inboard of the front and back articleedges 30, 32. In some configurations, the front and/or back edges of theupper and lower nonwoven layers may be positioned between the crimp seal500 and the inner core layer perimeter 200 a.

Suitable upper nonwoven layers may have a basis weight of from about 30gsm to about 85 gsm, or from about 30 to about 65 gsm, or from about 40to about 55 gsm. The upper nonwoven layer may have a Tensile Stiffnessof from about 0.3 N/mm to about 1.6 N/mm. The upper nonwoven layer mayhave a Strain to Break of greater than about 10%, or from about 10% toabout 50%, or from about 20% to about 40%. The upper nonwoven layer mayhave a Permanent Strain of about 0.005 to about 0.013 mm/mm, or from0.005 to about 0.0090 mm/mm.

Suitable lower nonwoven layers may have a basis weight of from about 10to about 40 gsm, or from about 15 to about 20 gsm. The lower nonwovenlayer may have a Tensile Stiffness of from about 0.2 N/mm to about 1.6N/mm. The lower nonwoven layer may have a Strain to Break of greaterthan about 10%, or from about 10% to about 50%, or from about 20% toabout 40%. The lower nonwoven layer may have a Permanent Strain of about0.005 to about 0.013 mm/mm.

The upper and lower nonwoven layers may comprise polymer fibers.Suitable upper and lower nonwoven fibers may be selected from PET(polyethylene terephthalate), PP (polypropylene), a BiCo (Bicomponentfiber) selected from PE/PP (PE sheath and PP core) and/or PE/PET (PEsheath PET core), PLA (polylactic acid), and combinations thereof.

Suitable upper nonwovens may comprise from about 60 to about 100%, orfrom about 70% to about 100% synthetic fibers, or from about 0 to about40% regenerated cellulosic fibers, such as rayon and/or viscose.

The upper nonwoven layer may comprise fibers having a staple length ofgreater than about mm, or greater than about 25 mm, or from about 10 mmto about 100 mm, or from about 20 mm to about 75 mm, or from about 25 mmto about 50 mm. The upper nonwoven layer may comprise fibers having afiber diameter of from about 1.3 DTex to about 10 DTex, alternativelyfrom about 1.3 DTex to about 6.0 DTex, alternatively from about 2.0 DTexto about 5.0 DTex. In some configurations, the upper nonwoven layer maycomprise fibers, wherein the fibers are a blend of staple fibers havinga fiber diameter of from about 2.0 DTex to about 10 DTex.

The lower nonwoven layer may comprise fibers having a length of greaterthan about 10 mm, or greater than about 25 mm, or from about 10 mm toabout 100 mm, or from about 20 mm to about 75 mm, or from about 25 mm toabout 50 mm. In some configurations, the lower nonwoven layer maycomprise continuous fibers. The lower nonwoven layer may comprise fibershaving a fiber diameter of from about 1.3 DTex to about 5.0 DTex,alternatively from about 1.3 DTex to about 3.3 DTex, alternatively fromabout 1.3 DTex to about 2.2 DTex, alternatively from about 2.0 DTex toabout 10 DTex. In some configurations, the lower nonwoven layer maycomprise fibers, wherein the fibers are a blend of fibers having a fiberdiameter of from about 0.1 DTex to about 6.0 DTex.

In some configurations, suitable fiber combinations may include uppernonwoven polymer fibers having a diameter of from about 2.0 DTex toabout 10 DTex and lower nonwoven polymer fibers having a diameter offrom about 1.7 DTex to about 5 DTex. In some configurations, suitablefiber combinations may include upper nonwoven polymer fibers having adiameter of from about 1.3 DTex to about 2.2 DTex and lower nonwovenpolymer fibers having a diameter of from about 1.7 DTex to about 5 DTex.

Suitable upper and lower nonwoven layer materials may bend and recovertheir original shape following the bending force Flimsy or highlyflexible materials readily bend at low peak force (load) and with lowbending energy. Unsuitable materials, while readily bending, do not havesufficient recovery energy and so retain a deformed, bent state becauseof insufficient recovery energy. Suitable materials have sufficientenergy to recover their initial pre-bent state. The materials withsufficient bending recovery energy may be considered resilient upper andlower nonwoven layers.

As noted above, the upper and lower nonwovens may include polymerfibers. Polymer fibers may be included to help provide structuralintegrity to the upper and lower nonwovens. The polymer fibers may helpincrease structural integrity of the upper and lower nonwovens in both amachine direction (MD) and in a cross-machine direction (CD), which mayfacilitate web manipulation during processing of the upper and lowernonwovens for incorporation into a pad.

Polymer fibers of any suitable composition may be selected. Someexamples of suitable polymer fibers may include bi-component fiberscomprising polyethylene (PE) and polyethylene terephthalate (PET)components or polyethylene terephthalate and co-polyethyleneterephthalate components. The components of the bi-component fiber maybe arranged in a sheath-core configuration, a side-by-sideconfiguration, an eccentric sheath-core configuration, a trilobalarrangement, or any other desired configuration. In some configurations,the polymer fibers may include bi-component fibers having PE/PETcomponents arranged in a concentric, sheath-core configuration, whereinthe polyethylene component forms the sheath.

While other materials may be useful in creating a resilient structure,it is believed that the stiffness of a PET core component in asheath-core fiber configuration is useful for imparting resilience tothe upper and lower nonwovens. In synergistic combination, a PE sheathcomponent, having a lower melting temperature than the PET corecomponent, may be utilized to provide inter-fiber melt/fusion bonding,effected via heat treatment of the precursor batt. This can help providetensile strength to the web in both the MD and CD. Such inter-fiberbonds may serve to reduce fiber-to-fiber sliding, and thereby furthercontribute to imparting shape stability and resiliency to the materialeven when it is wetted.

Where a relatively higher weight fraction of polymer fibers is included,more connections within the structure may be created via heat treatment.However, too many connection points may impart greater stiffness to theupper and lower nonwovens than may be desirable. For this reason,selecting the weight fraction of the polymer fibers may involveprioritizing and balancing competing needs for stiffness and softness inthe upper and lower nonwovens.

As noted above, the upper and lower nonwovens may additionally includepolymer fibers which increase resiliency of the upper and lowernonwovens. The resilient polymer fibers may help the upper and lowernonwovens maintain permeability and compression recovery. In someconfigurations, the upper and lower nonwovens may comprise resilientpolymer fibers having varying cross sections, e.g., round and hollowspiral, and/or may comprise resilient fibers having varying sizes.

The polymer fibers may be resilient and may be spun from any suitablethermoplastic resin, such as polypropylene (PP), polyethyleneterephthalate (PET), or other suitable thermoplastics known in the art.The average staple length of the resilient polymer fibers may beselected to be in the range of greater than about 10 mm, from about 20mm to about 100 mm, or about 30 mm to about 50 mm, or about 35 mm toabout 50 mm. The resilient polymer fibers may have any suitablestructure or shape. For example, the resilient polymer fibers may beround or have other shapes, such as spiral, scalloped oval, trilobal,scalloped ribbon, and so forth. Further, the resilient polymer fibersmay be solid, hollow, or multi-hollow. The resilient polymer fibers maybe solid and round in shape. In other suitable examples, resilientpolymer fibers may include polyester/co-extruded polyester fibers. Othersuitable examples of resilient polymer fibers may include bi-componentfibers such as polyethylene/polypropylene, polyethylene/polyethyleneterephthalate, polypropylene/polyethylene terephthalate bicomponentfibers. These bi-component fibers may have a sheath/core configuration.

The resilient polymer fibers may also be polyethylene terephthalate(PET) fibers, or other suitable non-cellulosic fibers known in the art.PET fibers may be imparted with any suitable structure or shape. Forexample, the PET fibers may be round or have other shapes, such asspiral, scalloped oval, trilobal, scalloped ribbon, hollow spiral, andso forth. The PET fibers may be solid, hollow or multi-hollow. In oneparticular example, PET fibers may be hollow in cross section and have acurl or spiral configuration along their lengths. Optionally, theresilient polymer fibers may be spiral-crimped or flat-crimped. Theresilient polymer fibers may have an average crimp count of about 4 toabout 12 crimps per inch (cpi), or about 4 to about 8 cpi, or about 5 toabout 7 cpi, or about 9 to about 10 cpi. Particular non-limitingexamples of resilient polymer fibers may be obtained from Wellman, Inc.(Ireland) under the trade designations H1311 and T5974. Other examplesof suitable resilient polymer fibers are disclosed in U.S. Pat. No.7,767,598.

The stiffening polymer fibers and resilient polymer fibers should becarefully selected. For example, while the constituent polymers formingthe stiffening polymer fibers and the resilient polymer fibers may havesimilarities, resilient polymer fiber composition should be selectedsuch that their constituents' melting temperature(s) is/are higher thanthat of the bondable components of the stiffening polymer fibers.Otherwise, during heat treatment, resilient polymer fibers could bond tostiffening polymer fibers and vice versa, and thereby an overly rigidstructure. To avoid this risk where the stiffening polymer fibersinclude bicomponent fibers, e.g., core-sheath configuration fibers witha sheath component of relatively lower melting temperature at whichfusion bonding will occur, the resilient polymer fibers may comprise theconstituent chemistry of only the core, which may be a polymer having arelatively higher melting temperature.

Nonwoven performance can be impacted by a combination of the nonwovenfiber polymer choice, fiber properties and how the fibers are arrangedor connected. Nonwoven selection can impact the absorbent article'sability to recover its shape following compression, bending andextension (stretching) forces present in-use with body motion. If thefibers are short fibers (less than about 10 mm) then they are likely toirreversibly rearrange under extension and compressive forces. Therearranging (changing their orientation/state) of fibers in a fibermatrix dissipates the tensile (elongation) or compressive forces so thatthe energy used to affect the deformation is no longer available forrecovery to the original shape. Longer fiber networks (typically greaterthan about 10 mm but less than about 100 mm) can dissipate thetensile/compressive forces typical of bodily motions along the fiberlength and across the structure. As a result, the imparted forces areavailable to recover the structure to its original state. Longer fibernetworks composed of finer fibers (less than about 15 to about 20microns and about 2.0 DTex) more readily elongate and compress. As aresult, the fluff/AGM structure can deform more readily (and to a higherdegree) but the energy associated with these deformations is relativelysmall and insufficient to carry the structure back to its originalstate. Thicker fiber, such as greater than about 2.0 DTex to about 10DTex, are both flexible under bodily forces but provide sufficient fiberand web recovery energy to return the structure to its original state.

The fiber arrangement in a long fiber network from a structuralstandpoint can impact the performance of the absorbent articlescontaining these nonwovens. Long fiber webs of thicker fibers aretypically loftier than a conventional thin spunbond nonwoven webcomposed of continuous fine fibers that are closely spaced andphysically bonded together. Creating a web of thicker fibers arranged ina more randomized orientation such as those that can be achieved viacarding, hydro-entangling and needling are able to elongate andcompress, whereby the fibers only temporary adjust their arrangement(space between the fibers exist for these arrangements) and are able tocarry/store the deformation forces and this energy is available forrecovering the structural shape.

Additionally finer (less than about 2.0 DTex) synthetic fibers such asBiCo and PP fibers commonly found in spunbond are closely spaced,relatively parallel aligned and closely bonded together. The bondedfibers within these spunbond webs are so interconnected (with closelyspaced point bonds) that in tensile (elongation) the fibers at thepolymer level are forced to stretch this results in polymer chainswithin the fiber permanently rearranging and as a result the fibersthemselves potentially remaining permanently elongated (permanentlystrained) and no longer able to recover to their initial state.

In some configurations, the polymer fibers in the upper nonwoven layerand the polymer fibers of the lower nonwoven layer may be different. Insome configurations, the polymer fibers of the upper nonwoven layer andthe polymer fibers of the lower nonwoven layer may be the same.

Suitable nonwoven materials examples include, but are not limited to,the following materials: (i) a 40 gsm carded resilient nonwoven materialproduced by Yanjan China (material code; ATB Z87G-40-90) which is acarded nonwoven composed of a blend of 60% 2 DTex and 40% 4 DTex BiCo(PE/PET) fibers. The fibers are bonded (ATB=Through ‘hot’ Air Bonded) tocreate a wet resilient network. The material basis weight is 40 gsm andits caliper (under 7 KPa) is about 0.9 mm Without being limited bytheory, it is believed that because of the presence of the 4 DTex BiCofibers and the fiber-to-fiber bonded BiCo network, the material has alow Permanent Strain (less than about 0.013 mm/mm) and a sufficient DryRecovery Energy (greater than about N*mm) in the Wet and Dry CD UltraSensitive 3 Point Bending Method; (ii) a 55 gsm resilient spunlacematerial produced by Sandler Germany (material code: 53FC041001), whichis a hydro-entangled nonwoven that is produced via a carding step (likethe nonwoven described above) followed by hydro-entangling with anelevated drying step (as described in U.S. Patent Publication No.2020/0315873A1) that creates both an entangled and BiCo bonded resilientnetwork. It comprises a fiber blend of 30% 10 DTex HS-PET, 50% 2.2 DTexBiCo (PE/PET), and 20% 1.3 DTex rayon. As such the material has a lowPermanent Strain (less than about 0.013 mm/mm) and a sufficient DryRecovery Energy (greater than about 0.03 N*mm) in the Wet and Dry CDUltra Sensitive 3 Point Bending Method; and (iii) a 50 gsm resilientspunlace material produced by Sandler Germany (material code: 53FC041005opt82), which is a hydro-entangled nonwoven that is produced via acarding step (like the nonwoven described above) followed byhydro-entangling with an elevated drying step (as described in U.S.Patent Publication No. 2020/0315873A1) that creates both an entangledand BiCo bonded resilient network. It comprises a fiber blend of 60%DTex BiCo (PE/PET), 20% 3.3 DTex tri-lobal ‘structural’ rayon, and 20%1.3 DTex rayon. As such the material has a low Permanent Strain (lessthan about 0.013 mm/mm) and a sufficient Dry Recovery Energy (greaterthan about 0.03 N*mm) in the Wet and Dry CD Ultra Sensitive 3 PointBending Method. While this material has 40% rayon that can soften whenwet, the use of structural tri-lobal rayon fibers helps structuralstability in the wet state.

In combination with adjustment of pore size, volume, and number viaselection of appropriate fiber size, basis weight, and extent ofconsolidation, the manufacturer may wish to select fiber constituentsfor having particular surface chemistry(ies), e.g., fibers withhydrophobic surfaces, hydrophilic surfaces, or a blend of differingfibers and/or z-direction stratification or gradient thereof. Fibershaving hydrophilic surfaces will tend to attract and move aqueouscomponents of menstrual fluid there along in a manner conducive towicking and rapid fluid acquisition following discharge. At the sametime, however, a predominance of hydrophilic fibers surfaces within thetopsheet may increase a tendency of the topsheet to reacquire fluid fromabsorbent components beneath (rewet), which can cause an undesirable wetfeel for the user. On the other hand, fibers having hydrophobic surfaceswill tend to repel aqueous components of menstrual fluid and/or resistmovement of fluid along their surfaces, thereby tending to resistwicking—but also to resist rewetting. The manufacturer may wish to seekan appropriate balance in selecting constituent fibers havinghydrophilic surfaces, fibers having hydrophobic surfaces, or a blendand/or z-direction stratification thereof, in combination with fibersize, fiber consolidation level, and resulting topsheet pore size,volume and number, for any particular product design.

The inner core layer is produced in an airlaying process. Streams ofcellulose fiber and AGM are carried on a fast moving airstream anddeposited into a three dimensionally shaped pocket on a rotating formingdrum with a vacuum below to draw the cellulose and AGM into the pocketin a laydown station. This shaped pocket provides the actual physicalshape of the absorbent core structure. The upper or lower nonwoven maybe first introduced onto the forming drum and under the vacuum the upperor lower nonwoven are drawn into the 3-dimensional pocket shape. In thiscase, the cellulose and AGM material stream is deposited on the upper(or lower nonwoven material) directly in the forming station. Prior toentering the forming station, the nonwoven is coated with an adhesive toprovide a stronger connection of the cellulose and AGM to the nonwovenlayer. On exiting the laydown section, the second remaining nonwovenlayer is combined with the nonwoven carrying the cellulose and AGM layerexiting the laydown section. This second remaining nonwoven (eitherupper or lower nonwoven depending on what nonwoven is run through thelaydown section) is precoated with adhesive to enable a perimeter sealand to better integrate the cellulose and AGM without hindering the flowof liquid into the cellulose and AGM matrix. In another approach, anonwoven is not first introduced into the forming station and thecellulose and AGM mass is held on the forming drum under vacuum until itis ejected onto either the upper or lower nonwoven layer that has anadhesive applied as detailed above and then sealed with the secondremaining nonwoven to create the absorbent core structure. The width ofthe upper and lower nonwoven webs are typically chosen to be wider thanthe maximum width of the shaped cellulose and AGM matrix so as to enablean effective perimeter seal where the two nonwovens connect, at least onthe left and right most sides of the absorbent core structure.

In yet another approach, neither the upper or lower nonwovens are drawninto the 3-dimensional pocket but rather the cellulose and AGM aredeposited directly onto a 3-dimensional forming screen. The upper orlower nonwoven is coated with an adhesive to provide a strongerconnection of the cellulose and AGM to the nonwoven layer and thecellulose/AGM matrix is directly deposited onto the nonwoven near theoutlet of the forming drum so as to minimize material loss before thesecond nonwoven is combined with the first nonwoven and the accompanyingfluff/AGM matrix.

The inner core layer may comprise any of a wide variety of liquidabsorbent materials commonly used in absorbent articles, such ascomminuted wood pulp, which is generally referred to as airfelt. Onesuitable absorbent core material is an airfelt material which isavailable from Weyerhaeuser Company, Washington, USA, under Code No.FR516. Examples of other suitable liquid absorbent materials for use inthe absorbent core may include creped cellulose wadding; meltblownpolymers including coform; chemically stiffened, modified orcross-linked cellulosic fibers; synthetic fibers such as crimpedpolyester fibers; peat moss; cotton, bamboo; absorbent polymermaterials; or any equivalent material or combinations of materials, ormixtures of these.

Absorbent polymer materials for use in absorbent articles typicallycomprise water-insoluble, water-swellable, hydrogel-forming crosslinkedabsorbent polymers which are capable of absorbing large quantities ofliquids and of retaining such absorbed liquids under moderate pressure.

The absorbent polymer material for the absorbent cores according to thepresent disclosure may comprise superabsorbent particles, also known as“superabsorbent materials” or as “absorbent gelling materials”.Absorbent polymer materials, typically in particle form, may be selectedamong polyacrylates and polyacrylate based materials, such as forexample partially neutralized, crosslinked polyacrylates. The term“particles” refers to granules, fibers, flakes, spheres, powders,platelets and other shapes and forms known to persons skilled in the artof superabsorbent particles. In some aspects, the superabsorbentparticles may be in the shape of fibers, i.e., elongated, acicularsuperabsorbent particles.

In some configurations, the inner core layer may comprise cellulosicfibers and superabsorbent particles. The inner core layer may comprisefrom about 50% to about 85% cellulosic fibers, or from about 55% toabout 80%, or from about 60% to about 75%, all by weight of the innercore layer. The inner core layer may comprise from about 10% to about50% superabsorbent particles, or from about 15% to about 50%, or fromabout 20% to about 40%, or from about 25% to about 35%, all by weight ofthe inner core layer. Preferably, the inner core layer may comprise fromabout 125 gsm to about 400 gsm cellulosic fibers.

In some configurations, the inner core layer may comprise from about 50%to about 85% cellulosic fibers and from about 15% to about 50%superabsorbent particles. The resulting absorbent core structure mayhave an average density of between about 0.045 g/cm³ and about 0.15g·cm³, and/or between 0.045 g/cm³ and 0.12 g/cm³. The absorbent articlemay have an average density of between about 0.045 g/cm³ and about 0.16g/cm³.

The absorbent core structures may compress and recover their originalshape following the compression step. Suitable absorbent core structuresrequire a low force to compress (less resistance) and the structure isable to recover its shape as the user, in a cyclic fashion, compressesand releases the compressive force with various body movements. Toachieve this, the structure sustains sufficient recovery energyfollowing multiple cyclic compressions. Without sufficient recoveryenergy the structure remains in a compressed bunched state withinsufficient force (stored energy) to recover.

As shown in FIGS. 1 and 7 , the absorbent core structure may comprise aplurality of structural bond sites 15. The structural bond sites 15 maybe symmetric and/or asymmetrical and may be any shape including, but notlimited to, circles, ovals, hearts, diamonds, triangles, squares, stars,and/or X shaped. The structural bond sites 15 may be on the absorbentarticle and/or on the absorbent core structure. In some configurations,the structural bond sites may have a bond area of from about 2 mm² toabout 5 mm². In some configurations, the total structural bond area maybe from about 0.5% to about 5%, or from about 0.75% to about 4.5%, orfrom about 1% to about 4% of the absorbent core structure, as measuredaccording to the Structural Bond Sites Pattern Spacing and AreaMeasurement Method. In some configurations, the total structural bondarea may be from about 1% to about 4% of absorbent article as measuredaccording to the Structural Bond Sites Pattern Spacing and AreaMeasurement Method. The average distance between the structural bondsites may be from about 10 mm to about 32 mm. In some configurations,the average distance between the structural bond sites may be greaterthan about 20 mm. In some configurations, the structural bond sites mayhave a maximum width of from about 1 mm to about 6 mm, or from about 1.5mm to about 5 mm, or from about 2 mm to about 4 mm Without being limitedby theory, it is believed that the average distance between structuralbond sites and/or the size of the structural bond sites may help tomaintain the structural integrity of the absorbent core structurewithout creating an undesirable stiffness that may inhibit the abilityof the absorbent article to conform to the body.

In some configurations, the structural bond sites may be distributedacross the absorbent article and/or absorbent core structure or they maybe clustered in regions of the absorbent article and/or absorbent corestructure. In some configurations, the structural bond sites may beclustered in the middle region 22 of the absorbent article and/orabsorbent core structure. In some configurations, the middle region 22of the absorbent article and/or absorbent core structure may be freefrom structural bond sites and may be surrounded by an area ofstructural bond sites and/or embossing. The structural bond sites 15 mayjoin the topsheet 110, the upper nonwoven layer 210, the absorbent corestructure 10, and the lower nonwoven layer 220. In some configurations,the structural bond sites 15 may join the upper nonwoven layer 210, theabsorbent core structure 10, and the lower nonwoven layer 220.

In some configurations, the absorbent article and/or absorbent corestructure may be free of structural bond sites.

Suitable absorbent articles and/or absorbent core structures maycomprise an upper nonwoven layer and lower nonwoven layer that arecloser together in the Z direction at the structural bond sites but arenot melted together. Since these structural bond sites are not meltedtogether, they may not be permanent in nature and rather may interminglethe materials within the structural bond site. In some configurations,the structural bond sites may be substantially free of fusion bonds.

Referring to FIG. 7 , in some configurations, the absorbent article maycomprise one or more flex bond channel regions 160, wherein the flexbond channel regions may be a continuous depression and/or a series ofindividually compressed, closely spaced embossments. In someconfigurations, the flex bond channel region may comprise an inner flexbond channel region and an outer flex bond channel region.

In some configurations, side edges 120 and 125 of the absorbent articlemay follow the general contour of the inner core layer 200. However,forms are contemplated where the side edges 120 and 125 are generallystraight or slightly curved such that they do not follow the contour ofthe inner core layer 200. The absorbent article 20 may be symmetricabout the longitudinal centerline 80 or asymmetric about thelongitudinal centerline 80. Similarly, the absorbent article may besymmetric about the lateral centerline 90 or asymmetric about thelateral centerline 90. The absorbent article 20 may be resilient andconformable and may deliver a superior in-use experience withoutsubstantially bunching and/or compressing. The absorbent article may beexposed to bodily forces and may recover to its original state. Theabsorbent article may have a CD Dry Modulus of between about 0.07 and0.30 N/mm² as measured in the Wet and Dry CD and MD 3 Point Bend Method,or from about 0.10 to about 0.25 N/mm², or from about 0.10 to about 0.20N/mm².

The absorbent article may have a of Dry Caliper between about 2.0 mm andabout 6.0 mm, or from about 2.0 mm and about 4.5 mm, or from about 2.5mm to about 4.0 mm, or from about 2.75 mm to about 3.5 mm, as measuredaccording to the Wet and Dry CD and MD 3-Point Method. In someconfigurations, the absorbent article may have a CD Dry Modulus ofbetween about 0.07 and 0.30 N/mm² and a Dry Caliper between about 2.0 mmand about 4.5 mm as measured according to the Wet and Dry CD and MD3-Point Method, or a CD Dry Modulus of between from about to about 0.25N/mm² and a Dry Caliper of from about 2.50 mm to about 4.0 mm, or a CDDry Modulus of between about from about 0.10 to about 0.20 N/mm² and aDry Caliper of from about 2.75 mm to about 3.5 mm. The absorbent articlemay have a CD Dry Bending Stiffness of between about 10.0 to about 30.0N*mm² as measured in the Wet and Dry CD and MD 3 Point Bend Method, orabout 10.0 and about 25.0 N*mm², or about 10 to about 20 N*mm², or about13 to about 20 N*mm². Particularly suitable absorbent articles includethose having a CD Dry Bending Stiffness of between about 10.0 and about30.0 N*mm² and a Dry Caliper of from about 2.5 mm to about 4.0 mm asmeasured according to the Wet and Dry CD and MD 3-Point Method, or a CDDry Bending Stiffness of about 10 to about 25 N*mm² and a Dry Caliper ofbetween about 2.5 and 4.0 mm, or a CD Dry Bending Stiffness about 13 toabout 30 N*mm² and a Dry Caliper of from about 2.75 mm to about 3.5 mm.

The absorbent article may have a 5^(th) Cycle Wet Energy of Recovery offrom about 1.0 to 3.5 N*mm, or about 1.5 to about 3.0 N*mm, or about 1.5to about 2.8 N*mm Particularly suitable absorbent articles may have a5^(th) Cycle Wet Energy of Recovery of between about 1.0 and 3.5 N*mmand a 5^(th) Cycle Wet % Recovery of from about 29% to about 40%, or a5^(th) Cycle Wet Energy of Recovery of from about 1.5 to about 3.0 N*mmand a 5^(th) Cycle Wet % Recovery of from about 29% to about 40%, or a5^(th) Cycle Wet Energy of Recovery from about 1.5 to about 2.75 N*mmand a 5^(th) Cycle Wet % Recovery of from about 29% to about 40%.

Absorbent articles comprising the absorbent core structures as disclosedherein may also need to deliver a dry touch to the consumer followingthe addition of fluid as measured by the light touch rewet method.Absorbent core structures and absorbent articles meeting the abovecharacteristics are designed to comfortably and gently conform moreclosely and more completely to the wearer's complex anatomical genitalshape. Such absorbent articles therefore may also need to be dry to thetouch following discharge so as not to irritate the sensitive genitaltissues. As such absorbent articles described herein may also maintain aLight Touch Rewet value of less than about 0.15 grams, or less about0.12 grams, or from about 0 to about 0.15 grams, or from about 0 toabout grams.

Topsheet

Topsheet 110 may be formed of any suitable nonwoven web or formed filmmaterial. Referring back to the figures, the topsheet 110 is positionedadjacent a wearer-facing surface of the absorbent article 20 and may bejoined thereto and to the backsheet 130 by any suitable attachment orbonding method. The topsheet 110 and the backsheet 130 may be joineddirectly to each other in the peripheral regions outside the perimeterof the absorbent core structure and may be indirectly joined by directlyjoining them respectively to wearer-facing and outward-facing surfacesof the absorbent article or additional optional layers included with theabsorbent article.

The absorbent article 20 may have any known or otherwise effectivetopsheet 110, such as one which is compliant, soft feeling, andnon-irritating to the wearer's skin. A suitable topsheet material willinclude a liquid pervious material that is comfortable when in contactwith the wearer's skin and permits discharged menstrual fluid to rapidlypenetrate through it. Some suitable examples of topsheet materialsinclude films, nonwovens, laminate structures including film/nonwovenlayers, film/film layers, and nonwoven/nonwoven layers.

Nonlimiting examples of nonwoven web materials that may be suitable foruse to form the topsheet 110 include fibrous materials made from naturalfibers, modified natural fibers, synthetic fibers, or combinationsthereof. Some suitable examples are described in U.S. Pat. Nos.4,950,264; 4,988,344; 4,988,345; 3,978,185; 7,785,690; 7,838,099;5,792,404; and 5,665,452.

The topsheet 110 may be compliant, soft feeling, and non-irritating tothe wearer's skin. Further, the topsheet 110 may be liquid perviouspermitting liquids (e.g., urine, menses) to readily penetrate throughits thickness. Some suitable examples of topsheet materials includefilms, nonwovens, laminate structures including film/nonwoven layers,film/film layers, and nonwoven/nonwoven layers. Other exemplary topsheetmaterials and designs are disclosed in U.S. Patent ApplicationPublication Nos. 2016/0129661, 2016/0167334, and 2016/0278986.

In some examples, the topsheet 110 may include tufts as described inU.S. Pat. Nos. 8,728,049; 7,553,532; 7,172,801; 8,440,286; 7,648,752;and 7,410,683. The topsheet 20 may have a pattern of discrete hair-likefibrils as described in U.S. Pat. No. 7,655,176 or U.S. Pat. No.7,402,723. Additional examples of suitable topsheet materials includethose described in U.S. Pat. Nos. 8,614,365; 8,704,036; 6,025,535; andUS Patent Publication No. 2015/041640. Another suitable topsheet may beformed from a three-dimensional substrate as detailed in US2017/0258647. The topsheet may have one or more layers, as described inUS Patent Publication Nos. 2016/0167334; US 2016/0166443; and US2017/0258651.

In some examples a topsheet 110 may be formed of a nonwoven web materialof a spunbond web including single-component continuous fibers, oralternatively, bi-component or multi-component fibers, or a blend ofsingle-component fibers spun of differing polymer resins, or anycombination thereof. The topsheet may also be a formed nonwoven topsheetas disclosed in US Patent Publication No. 2019/0380887.

In order to ensure that fluid contacting the top (wearer-facing) surfaceof a topsheet will move suitably rapidly in a z-direction to the bottom(outward-facing) surface of the topsheet where it can be drawn into theabsorbent article, it may be important to ensure that the nonwoven webmaterial forming the topsheet has an appropriate weight/volume density,reflecting suitable presence of interstitial passageways (sometimesknown as “pores”) among and between the constituent fibers, throughwhich fluid may move within the nonwoven material. In some circumstancesa nonwoven material with fibers that are consolidated too densely mayhave insufficient numbers and/or volumes and/or sizes of pores, and thenonwoven will obstruct rather than facilitate rapid downward z-directionfluid movement. On the other hand, a nonwoven with fibers that are toolarge and/or not consolidated enough to provide a certain level ofopacity (for purposes of concealing absorbed fluid in the layersbeneath) and a substantial appearance may be negatively perceived byusers.

The caliper of the topsheet material may be controlled, to balancecompeting needs for opacity and loft (which call for a higher caliper)vs. a limitation on the z-direction distance that discharged fluidtravels through the topsheet from the wearer-facing surface to theoutward-facing surface, to reach the absorbent core components below.Thus, it may be desired that the manufacture of the topsheet material becontrolled to produce a topsheet material having a caliper of from about0.20 mm to about 1.0 mm, or from about 0.25 mm to about 0.80 mm, or fromabout mm to about 0.60 mm.

Secondary Topsheet (STS)

An STS layer may be included, in some circumstances, between thetopsheet and the absorbent core structure to enable the absorbent corestructure to readily receive a sudden discharge of fluid, and afterreceipt, to wick it along x- and y-directions to distribute it acrossthe underlying absorbent core structure.

If included, an STS may be a nonwoven fibrous structure which mayinclude cellulosic fibers, non-cellulosic fibers (e.g., fibers spun frompolymer resin(s)), or a blend thereof. To accommodate the folding andlateral gathering of the absorbent article 20, and of the absorbent corestructure 10, as described herein, the STS may be formed of a materialthat is relatively pliable (i.e., has relatively low bending stiffness).

A number of particular examples of suitable STS compositions andstructures, as well as combinations thereof with suitable topsheetcompositions and structures, are further described in U.S. applications.Ser. Nos. 16/831,862; 16/831,854; 16/832,270; 16/831,865; 16/831,868;16/831,870; and Ser. No. 16/831,879; and U.S. Provisional Apps. Ser.Nos. 63/086,610 and 63/086,701. Additional suitable examples aredescribed in U.S. Pat. No. 9,504,613; WO 2012/040315; and US2019/0021917.

In some configurations, the absorbent article may be free of a secondarytopsheet.

Backsheet

The backsheet 130 may be positioned beneath or subjacent anoutward-facing surface of the absorbent core structure 10 and may bejoined thereto by any suitable attachment methods. For example, thebacksheet 130 may be secured to the absorbent core structure 10 by auniform continuous layer of adhesive, a patterned layer of adhesive, oran array of separate lines, spirals, or spots of adhesive.Alternatively, the attachment method may include heat bonds, pressurebonds, ultrasonic bonds, dynamic mechanical bonds, or any other suitableattachment mechanisms or combinations thereof. In other examples, it iscontemplated that the absorbent core structure 10 is not joined directlyto the backsheet 130.

The backsheet 130 may be impermeable or substantially impermeable byaqueous liquids (e.g., urine, menstrual fluid) and may be manufacturedfrom a thin plastic film, although other flexible liquid impermeablematerials may also be used. As used herein, the term “flexible” refersto materials which are compliant and will readily conform to the generalshape and contours of the human body. The backsheet 130 may prevent, orat least substantially inhibit, fluids absorbed and contained within theabsorbent core structure 10 from escaping and reaching articles of thewearer's clothing which may contact the absorbent article 20, such asunderpants and outer clothing. However, in some instances, the backsheet130 may be made and/or adapted to permit vapor to escape from theabsorbent core structure 10 (i.e., the backsheet is made to bebreathable), while in other instances the backsheet 130 may be made soas not to permit vapors to escape (i.e., it is made to benon-breathable). Thus, the backsheet 130 may comprise a polymeric filmsuch as thermoplastic films of polyethylene or polypropylene. A suitablematerial for the backsheet 130 is a thermoplastic film having athickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils),for example. Any suitable backsheet known in the art may be utilizedwith the present invention.

Some suitable examples of materials suitable for forming a backsheet aredescribed in U.S. Pat. Nos. 4,342,314; and 4,463,045. Suitable singlelayer breathable backsheets for use herein include those described forexample in GB A 2184 389; GB A 2184 390; GB A 2184 391; U.S. Pat. Nos.4,591,523; 3,989,867; 3,156,242; WO 97/24097; U.S. Pat. Nos. 6,623,464;6,664,439; and 6,436,508.

The backsheet 130 may have two layers: a first layer comprising a vaporpermeable aperture-formed film layer and a second layer comprising abreathable microporous film layer, as described in U.S. Pat. No.6,462,251. Other suitable examples of dual or multi-layer breathablebacksheets for use herein include those described in U.S. Pat. Nos.3,881,489; 4,341,216; 4,713,068; 4,818,600; EP 203 821; EP 710 471; EP710 472; and EP 0 793 952.

Other Features

In some configurations, the absorbent article 20 may be provided withadhesive deposits to provide a mechanism for the user to adhere theabsorbent article to the inside of her underpants in the crotch regionthereof. When the absorbent article 20 is packaged for shipping,handling and storage prior to use, adhesive deposits may be covered byone or more sheets of release film or paper (not shown) thatcovers/shields the adhesive deposits from contact with other surfacesuntil the user is ready to remove the release film or paper and placethe absorbent article in her underpants for wear/use.

In some configurations, the absorbent article 20 may include opposingwing portions 140, 150 on each side, extending laterally beyondlongitudinal edges of the absorbent portions of the absorbent article bya comparatively greater width dimension than that of the forward andrearward portions of the absorbent article. Wings are currently commonlyprovided with feminine hygiene absorbent articles. As provided, theytypically have deposits of adhesive applied to their outward-facingsurfaces (surface are outward-facing prior to placement of the absorbentarticle within the user's underwear and application of the wings). Thewing portions may also include deposits of adhesive as described above,which enable the user to wrap the wing portions through the leg openingsof the underpants and around the inside edges thereof, and adhere thewing portions to the outward-facing surface/underside of the underpantsin the crotch region, providing supplemental holding support for theabsorbent article and helping guard the underpants proximate the legedges thereof against soiling.

Test Methods Layers of Interest

For any of the methods below in which all the component layers of anarticle will not be tested, the layers of interest may be separatedusing cryo-spray as needed from layers which will not be tested.

Strain to Break Method

The force versus displacement behavior of a sample is measured on auniversal constant rate of extension test frame (a suitable instrumentis the MTS Alliance using TestSuite Software, as available from MTSSystems Corp., Eden Prairie, MN, or equivalent) equipped with a loadcell for which the forces measured are within 1% to 99% of the limit ofthe cell. The sample is subjected to tensile elongation at a constantrate (mm/sec) until it breaks, and the percent strain to break ismeasured. All testing is performed in a room controlled at 23° C.±3C°and 50%±2% relative humidity and test samples are conditioned in thisenvironment for at least 2 hours prior to testing.

The fixtures used to grip the test specimen are lightweight (<80 grams),vise action clamps with half cylinder steel versus rubber coated steelgrip faces that are at least 40 mm wide. The fixtures are installed onthe universal test frame and mounted such that they are horizontally andvertically aligned with one another.

The test specimen is prepared as follows. Obtain the test material byexcising it from an absorbent article, if necessary. When excising thetest material, do not impart any contamination or distortion to thematerial layer during the process. The test specimen is cut from an areaon the test material that is free of any folds or wrinkles. The testspecimen is 100 mm long (parallel to the lateral axis, or intendedlateral axis of the article) and 25.4 mm wide (parallel to thelongitudinal axis, or intended longitudinal axis of the article). Inlike fashion, five replicate test specimens are prepared.

Prepare the universal test frame as follows. Set the initial grip togrip separation distance to a nominal gage length of 80 mm, then zerothe crosshead. Program the test frame to move the grips closer togetherby an intentional slack of 1 mm to ensure no pretension force exists onthe test specimen at the onset of the test. (During this motion, thespecimen will become slack between the grips.) Next, the grips will moveapart at a slack speed of 1 mm/s until the slack preload of 0.05 N isexceeded. (At this point, the crosshead position signal is used tocompute the sample slack, the adjusted gage length, and the strain isdefined at zero, 0.0). The grips will then move apart at a speed of 1mm/s until the sample breaks or the extension limit of the instrument isexceeded.

The test is executed by inserting the test specimen into the grips suchthat the long axis of the specimen is parallel and centered with themotion of the crosshead. Start the test and continuously collect force(“load”) and displacement data at a data acquisition rate of 100 Hz.

Construct a graph of load (N) versus displacement (mm). Determine thepeak load from the curve, then determine the break sensitivity asfollows. Determine the crosshead position at which the load signaldecreases by 75% after the peak load is reached, and record as specimenfinal length (Lf) to the nearest 0.01 mm. The initial length of thespecimen is defined by the crosshead position when the slack preload of0.05 N is exceeded, and this value is recorded as specimen initiallength (Li) to the nearest 0.01 mm Calculate the percent strain to breakas follows, and record to the nearest 1 percent.

% Strain to Break=((Lf−Li)/Li)*100

In like fashion, the procedure is repeated for all five replicate testspecimens. The arithmetic mean of % strain to break among the fivereplicate test specimens is calculated and reported as % Strain to Breakto the nearest 1 percent.

Wet and Dry CD and MD 3 Point Bend Method

The bending properties of an absorbent article test sample are measuredon a universal constant rate of extension test frame (a suitableinstrument is the MTS Alliance using TestSuite Software, as availablefrom MTS Systems Corp., Eden Prairie, MN, or equivalent) equipped with aload cell for which the forces measured are within 1% to 99% of thelimit of the cell. The test is executed on dry test specimens as well aswet test specimens. The intention of this method is to mimic deformationcreated in the x-y plane by a wearer of an absorbent article duringnormal use. All testing is performed in a room controlled at 23° C.±3°C. and 50%±2% relative humidity.

The bottom stationary fixture consists of two cylindrical bars 3.175 mmin diameter by 110 mm in length, made of polished stainless steel eachmounted on each end with frictionless roller bearings. These 2 bars aremounted horizontally, aligned front to back and parallel to each other,with top radii of the bars vertically aligned and are free to rotatearound the diameter of the cylinder by the frictionless bearings.Furthermore, the fixture allows for the two bars to be movedhorizontally away from each other on a track so that a gap can be setbetween them while maintaining their orientation. The top fixtureconsists of a third cylinder bar also 3.175 mm in diameter by 110 mm inlength, made of polished stainless steel mounted on each end withfrictionless roller bearings. When in place the bar of the top fixtureis parallel to and aligned front to back with the bars of the bottomfixture and is centered between the bars if the bottom fixture. Bothfixtures include an integral adapter appropriate to fit the respectiveposition on the universal test frame and lock into position such thatthe bars are orthogonal to the motion of the crossbeam of the testframe.

Set the gap (“Span”) between the bars of the lower fixture to 25 mm±0.5mm (center of bar to center of bar) with the upper bar centered at themidpoint between the lower bars. Set the gage (bottom of top bar to topof lower bars) to 1.0 cm.

The thickness (“caliper”) of the test specimen is measured using amanually-operated micrometer equipped with a pressure foot capable ofexerting a steady pressure of 0.1 psi±0.01 psi. The manually-operatedmicrometer is a dead-weight type instrument with readings accurate to0.01 mm A suitable instrument is Mitutoyo Series 543 ID-C Digimatic,available from VWR International, or equivalent. The pressure foot is aflat circular moveable face with a diameter no greater than 25.4 mm. Thetest specimen is supported by a horizontal flat reference platform thatis larger than and parallel to the surface of the pressure foot. Zerothe micrometer against the horizontal flat reference platform. Place thetest specimen onto the platform, centered beneath the pressure foot. Thepressure foot is lowered by hand with a descent rate of 3±1 mm/s untilthe full weight of the pressure is exerted onto the specimen. After 5seconds elapse, the thickness is recorded as caliper to the nearest 0.01mm.

The test fluid used to dose the wet test specimens is prepared by adding100.0 grams of sodium chloride (reagent grade, any convenient source) to900 grams of deionized water in a 1-liter Erlenmeyer flask. Agitateuntil the sodium chloride is completely dissolved.

The absorbent article samples are conditioned at 23° C.±3° C. and 50%±2%relative humidity two hours prior to testing. Dry test specimens aretaken from an area of the sample that is free from any seams and residuaof folds or wrinkles, and ideally from the center of absorbent article(intersection of longitudinal and lateral midlines). The dry specimensare prepared for MD (machine direction) bending by cutting them to awidth of 50.8 mm along the CD (cross direction; parallel to the lateralaxis of the sample) and a length of 50.8 mm along the MD (parallel tothe longitudinal axis of the sample), maintaining their orientationafter they are cut, and marking the body-facing surface (or the surfaceintended to face the body of a finished article). The dry specimens areprepared for CD (machine direction) bending by cutting them to a widthof 50.8 mm along the MD (cross direction; parallel to the lateral axisof the sample) and a length of 50.8 mm along the CD (parallel to thelongitudinal axis of the sample), maintaining their orientation afterthey are cut, and marking the body-facing surface (or the surfaceintended to face the body of a finished article). Measure the thicknessof the test specimen, as described herein, and record as dry specimencaliper to the nearest 0.01 mm Now measure the mass of the test specimenand record as dry mass to the nearest 0.001 grams. Calculate the basisweight of the specimen by dividing the mass (g) by the area (0.002581m²) and record as dry specimen basis weight to the nearest 0.01 g/m².Calculate the bulk density of the specimen by dividing the specimenbasis weight (g/m²) by the specimen thickness (mm), then dividing thequotient by 1000, and record as dry specimen density to the nearest 0.01g/cm³. In like fashion, five replicate dry test specimens are prepared.

Wet test specimens are initially prepared in the exact manner as for thedry test specimen, followed by the addition of test fluid just prior totesting, as follows. First, the thickness and mass of the dry specimenis measured, as described herein, and recorded as initial thickness tothe nearest mm and initial mass to the nearest 0.001 g. Next, the dryspecimen is fully submersed in the test fluid for 60 seconds. After 60seconds elapse, the specimen is removed from the test fluid and orientedvertically for 30 seconds to allow any excess fluid to drip off. Now thethickness and mass of the wet specimen are measured, as describedherein, and recorded as wet specimen caliper to the nearest 0.01 mm andwet specimen mass to the nearest 0.001 g. If desired, the mass of testfluid in the test specimen is calculated by subtracting the initial mass(g) from the wet specimen mass (g) and recording as test specimen fluidamount to the nearest 0.001 g. After the wet test specimen is removedfrom the test fluid, it must be tested within 10 minutes. In likefashion, five replicate wet test specimens are prepared.

Program the universal test frame for a flexural bend test, to move thecrosshead such that the top fixture moves down with respect to the lowerfixture at a rate of 1.0 mm/sec until the upper bar touches the topsurface of the specimen with a nominal force of 0.02 N, then continuefor an additional 12 mm. The crosshead is then immediately returned tothe original gage at a rate of 1.0 mm/s. Force (N) and displacement (mm)data are continuously collected at 100 Hz throughout the test.

Load a dry test specimen such that it spans the two lower bars and iscentered under the upper bar, with its sides parallel to the bars. ForMD bending, the MD direction of the test specimen is perpendicular tothe length of the 3 bars. Start the test and continuously collect forceand displacement data.

Construct a graph of force (N) versus displacement (mm). From the graph,determine the maximum peak force and record as dry MD peak load to thenearest 0.01 N. Now calculate the maximum slope of the curve betweeninitial force and maximum force (during the loading portion of thecurve) and record to the nearest 0.1 unit. Calculate the modulus asfollows, and record as dry MD modulus to the nearest 0.001 N/mm².

CD or MD Dry or Wet Bending Modulus(N/mm²)=(Slope×(Span³))/(4×specimenwidth×

(specimen caliper³))

-   -   Calculate bending stiffness as follows, and record as dry MD        bending stiffness to the nearest 0.1 N mm².

CD or MD Dry or Wet Bending Stiffness (N mm²)=Modulus×Moment of Inertia

where Moment of Inertia (mm⁴)=(specimen width×(specimen caliper³))/12

In like fashion, the procedure is repeated for all five replicates ofthe dry test specimens. The arithmetic mean among the five replicate drytest specimens is calculated for each of the parameters and reported asDry Specimen ‘Caliper’ to the nearest 0.01 mm, Dry Specimen Basis Weightto the nearest 0.01 g/m², Dry Specimen Density to the nearest 0.001g/cm³, Dry CD or MD Peak Load to the nearest 0.01 N, Dry CD or MDBending Modulus to the nearest 0.001 N/mm², and Dry CD or MD BendingStiffness to the nearest N mm².

The overall procedure is now repeated for all five replicates of the wettest specimens, reporting results as Wet CD or MD Peak Load to thenearest 0.01 N, Wet CD or MD Bending Modulus to the nearest 0.001 N/mm²,and Wet CD or MD Bending Stiffness to the nearest N mm².

Wet and Dry CD Ultra Sensitive 3 Point Bending Method

The CD (cross-direction) bending properties of a test sample aremeasured using an ultra sensitive 3 point bend test on a universalconstant rate of extension test frame (a suitable instrument is the MTSAlliance using TestSuite Software, as available from MTS Systems Corp.,Eden Prairie, MN, or equivalent) equipped with a load cell appropriatefor the forces being measured. The test is executed on dry testspecimens as well as wet test specimens. The intention of this method isto mimic deformation created in the x-y plane by a wearer of anabsorbent article during normal use. All testing is performed in a roomcontrolled at 23° C.±3° C. and 50%±2% relative humidity.

The ultra sensitive 3 point bend method is designed to maximize theforce signal to noise ratio when testing materials with very low bendingforces. The force signal is maximized by using a high sensitivity loadcell (e.g., 5N), using a small span (load is proportional to the spancubed) and using a wide specimen width (total measured load is directlyproportional to width). The fixture is designed such that the bendingmeasurement is performed in tension, allowing the fixture mass to bekept to a minimum. Noise in the force signal is minimized by holding theload cell stationary to reduce mechanical vibration and inertial effectand by making the mass of the fixture attached to the load cell as lowas possible.

Referring to FIGS. 10A-10C, the load cell 1001 is mounted on thestationary crosshead of the universal test frame. The ultra sensitivefixture 1000 consists of three thin blades constructed of a lightweight,rigid material (such as aluminum, or equivalent). Each blade has athickness of 1.0 mm, rounded edges and a length that is able toaccommodate a bending width of 100 mm Each of the blades has a cavity1004 a and 1004 b (outside blades) and 1005 (central blade) cut out tocreate a height, h, of 5 mm of blade material along their horizontaledges. The two outside blades 1003 a and 1003 b are mounted horizontallyto the moveable crosshead of the universal test frame, aligned parallelto each other, with their horizontal edges vertically aligned. The span,S, between the two outside blades 1003 a and 1003 b is 5 mm±0.1 mm(inside edge to inside edge). The central blade 1002 is mounted to theload cell on the stationary crosshead of the universal test frame. Whenin place, the central blade 1002 is parallel to the two outside blades1003 a and 1003 b and centered at the midpoint between the outsideblades 1003 a and 1003 b. The blade fixtures include integral adaptersappropriate to fit the respective positions on the universal test frameand lock into position such that the horizontal edges of the blades areorthogonal to the motion of the crossbeam of the universal test frame.

The test fluid used to dose the wet test specimens is prepared by adding100.0 grams of sodium chloride (reagent grade, any convenient source) to900 grams of deionized water in a 1-liter Erlenmeyer flask. Agitateuntil the sodium chloride is completely dissolved.

Samples are conditioned at 23° C.±3° C. and 50%±2% relative humidity twohours prior to testing. Dry test specimens are taken from an area of thesample that is free from any seams and residua of folds or wrinkles. Thedry specimens are prepared for CD bending (i.e., bending normal to thelateral axis of the sample) by cutting them to a width of 50.0 mm alongthe CD (cross direction; parallel to the lateral axis of the sample) anda length of 100.0 mm along the MD (machine direction; parallel to thelongitudinal axis of the sample), maintaining their orientation afterthey are cut and marking the body-facing surface (or the surfaceintended to face the body of a finished article). In like fashion, fivereplicate dry test specimens are prepared.

Wet test specimens are initially prepared in the exact manner as for thedry test specimen, followed by the addition of test fluid just prior totesting, as follows. The dry specimen is fully submersed in the testfluid for 60 seconds. After 60 seconds elapse, the specimen is removedfrom the test fluid and oriented vertically for 30 seconds to allow anyexcess fluid to drip off. After the wet test specimen is removed fromthe test fluid, it must be tested within 10 minutes. In like fashion,five replicate wet test specimens are prepared.

The universal test frame is programmed such that the moveable crossheadis set to move in a direction opposite of the stationary crosshead at arate of 1.0 mm/s. Crosshead movement begins with the specimen 1006 lyingflat and undeflected on the outer blades 1003 a and 1003 b, continueswith the inner horizontal edge of cavity 1005 in the central blade 1002coming into contact with the top surface of the specimen 1006, andfurther continues for an additional 4 mm of crosshead movement. Thecrosshead stops at 4 mm and then immediately returns to zero at a speedof 1.0 mm/s. Force (N) and displacement (mm) are collected at 50 Hzthroughout.

Prior to loading the test specimen 1006, the outside blades 1003 a and1003 b are moved towards and then past central blade 1002 until there isapproximately a 3 mm clearance, C, between the inner horizontal edges ofcavities 1004 a and 1004 b in the outside blades 1003 a and 1003 b andthe inner horizontal edge of cavity 1005 in the central blade 1002 (seeFIG. 10C). The specimen 1006 is placed within clearance C such that itspans the inner horizontal edges of cavities 1004 a and 1004 b in theoutside blades 1003 a and 1003 b, oriented such that the MD (short side)of the specimen is perpendicular to the horizontal edges of the bladesand the body-facing surface of the specimen is facing up. Center thespecimen 1006 between the outside blades 1003 a and 1003 b. Slowly movethe outside blades 1003 a and 1003 b in a direction opposite of thestationary crosshead until the inner horizontal edge of cavity 1005 inthe central blade 1002 touches the top surface of the specimen 1006.Start the test and continuously collect force and displacement data.

Force (N) is plotted versus displacement (mm). The maximum peak force isrecorded to the nearest 0.001 N. The area under the curve from loadonset up to the maximum peak force is calculated and recorded as bendingenergy to the nearest 0.001 N-mm. The recovery energy is calculated asthe area under the curve where the force is unloaded from the maximumpeak to 0.0 N and recorded as recovery energy to the nearest 0.001 N-mm.In like fashion, repeat the entire test sequence for a total of five drytest specimens and five wet test specimens.

For each test specimen type (dry and wet), the arithmetic mean of themaximum peak force among like specimens is calculated to the nearest0.001 N and recorded as Dry Peak Load and Wet Peak load, respectively.For each test specimen type (dry and wet), the arithmetic mean ofbending energy among like specimens is calculated to the nearest 0.001N-mm and reported as Dry Bending Energy and Wet Bending Energy,respectively. For each test specimen type (dry and wet), the arithmeticmean of recovery energy among like specimens is calculated to thenearest 0.001 N-mm and reported as Dry Recovery Energy and Wet RecoveryEnergy, respectively.

Wet and Dry Bunched Compression Method

The bunched compression test method measures the force versusdisplacement behavior across five cycles of load application(“compression”) and load removal (“recovery”) of an absorbent articletest sample that has been intentionally “bunched”, using a universalconstant rate of extension test frame (a suitable instrument is the MTSAlliance using TestSuite software, as available from MTS Systems Corp.,Eden Prairie, MN, or equivalent) equipped with a load cell for which theforces measured are within 1% to 99% of the limit of the cell. The testis executed on dry test specimens as well as wet test specimens that aredosed with a specified amount of test fluid. The intention of thismethod is to mimic the deformation created in the z-plane of the crotchregion of an absorbent article, or components thereof, as it is worn bythe wearer during sit-stand movements. All testing is performed in aroom controlled at 23° C.±3C° and 50%±2% relative humidity.

The test apparatus is depicted in FIGS. 11-12B. The bottom stationaryfixture 3000 consists of two matching sample clamps 3001 each 100 mmwide, each mounted on its own movable platform 3002 a, 3002 b. The clamphas a “knife edge” 3009 that is 110 mm long, which clamps against a 1 mmthick hard rubber face 3008. When closed, the clamps are flush with theinterior side of its respective platform. The clamps are aligned suchthat they hold an un-bunched specimen horizontal and orthogonal to thepull axis of the tensile tester. The platforms are mounted on a rail3003 which allows them to be moved horizontally left to right and lockedinto position. The rail has an adapter 3004 compatible with the mount ofthe tensile tester capable of securing the platform horizontally andorthogonal to the pull axis of the tensile tester. The upper fixture2000 is a cylindrical plunger 2001 having an overall length of 70 mmwith a diameter of 25.0 mm. The contact surface 2002 is flat with nocurvature. The plunger 2001 has an adapter 2003 compatible with themount on the load cell capable of securing the plunger orthogonal to thepull axis of the tensile tester.

Test samples are conditioned at 23° C.±3C° and 50%±2% relative humidityfor at least 2 hours before testing. Prepare the test specimen asfollows. When testing an intact absorbent article, remove the releasepaper from any panty fastening adhesive on the garment facing side ofthe article, if present. Lightly apply talc powder to the adhesive tomitigate any tackiness. If there are cuffs, excise them with scissors soas not to disturb the topsheet or any other underlying layers of thearticle. Place the article, body facing surface up, on a benchtop. Onthe article, mark the intersection of the longitudinal midline and thelateral midline. Using a rectangular cutting die or equivalent cuttingmeans, cut a specimen 100 mm in the longitudinal direction by 80 mm inthe lateral direction, centered at the intersection of the midlines.When testing a material layer or layered components from an absorbentarticle, place the material layer or layered components on a benchtopand orient as it would be integrated into a finished article, i.e.,identify the body facing surface and the lateral and longitudinal axis.Using a rectangular cutting die, or equivalent cutting means, cut aspecimen 100 mm in the longitudinal direction by 80 mm in the lateraldirection, centered at the intersection of the midlines. Measure themass of the specimen and record to the nearest 0.001 grams. Calculatethe basis weight of the specimen by dividing the mass (g) by the area(0.008 m²) and record as basis weight to the nearest 1 g/m².

The specimen can be analyzed both wet and dry. The dry specimen requiresno further preparation. The test fluid used to dose the wet testspecimens is prepared by adding 100.0 grams of sodium chloride (reagentgrade, any convenient source) to 900 grams of deionized water in a1-liter Erlenmeyer flask. Agitate until the sodium chloride iscompletely dissolved. The wet specimen is dosed with total of 7 ml ofthe test solution as detailed below

The liquid dose is added using a calibrated Eppendorf-type pipettor,spreading the fluid over the complete body facing surface of thespecimen within a period of approximately 3 sec. The wet specimen istested 10.0 min±0.1 min after the dose is applied.

Program the tensile tester to zero the load cell, then lower the upperfixture at 2.00 mm/sec until the contact surface of the plunger touchesthe specimen and 0.02 N is read at the load cell. Zero the crosshead.Program the system to lower the crosshead 15.00 mm at 2.00 mm/sec thenimmediately raise the crosshead 15.00 mm at 2.00 mm/sec. This cycle isrepeated for a total of five cycles, with no delay between cycles. Datais collected at 50 Hz during all compression/decompression cycles.

Position the left platform 3002 a 2.5 mm from the side of the upperplunger (distance 3005). Lock the left platform into place. Thisplatform 3002 a will remain stationary throughout the experiment. Alignthe right platform 3002 b 50.0 mm from the stationary clamp (distance3006). Raise the upper probe 2001 such that it will not interfere withloading the specimen. Open both clamps 3001. Referring to FIG. 12A,place the dry specimen with its longitudinal edges (i.e., the 100 mmlong edges) within the clamps. With the dry specimen laterally centered,securely fasten both edges in the clamps. Referring to FIG. 12B, movethe right platform 3002 b toward the stationary platform 3002 a adistance of 20 mm so that a separation of 30.0 mm between the left andright clamps is achieved. Allow the dry specimen to bow upward as themovable platform is positioned. Now manually lower the probe 2001 untilthe bottom surface is approximately 1 cm above the top of the bowedspecimen.

Start the test and continuously collect force (N) versus displacement(mm) data for all five cycles. Construct a graph of force (N) versusdisplacement (mm) separately for all cycles. A representative curve isshown in FIG. 13A. From the curve, determine the Dry Maximum CompressionForce for each Cycle to the nearest 0.01 N, then multiply by 101.97 andrecord to the nearest 1 gram-force. Calculate the Dry % Recovery betweenthe First and Second cycle as (TD−E2)/(TD−E1)*100 where TD is the totaldisplacement and E2 is the extension on the second compression curvethat exceeds 0.02 N, and record to the nearest 0.01%. In like fashioncalculate the Dry % Recovery between the First Cycle and other cycles as(TD−E1)/(TD−E1)*100 and record to the nearest 0.01%. Referring to FIG.13B, calculate the Dry Energy of Compression for Cycle 1 as the areaunder the compression curve (i.e., area A+B) and record to the nearest0.1 N-mm Calculate the Dry Energy Loss from Cycle 1 as the area betweenthe compression and decompression curves (i.e., Area A) and record tothe nearest 0.1 N-mm Calculate the Dry Energy of Recovery for Cycle 1 asthe area under the decompression curve (i.e., Area B) and report to thenearest 0.1 N-mm. In like fashion calculate the Dry Energy ofCompression (N-mm), Dry Energy Loss (N-mm) and Dry Energy of Recovery(N-mm) for each of the other cycles and record to the nearest 0.1 N-mm.In like fashion, analyze a total of five replicate dry test specimensand report the arithmetic mean among the five dry replicates for eachparameter as previously described, including basis weight.

The overall procedure is now repeated for a total of five replicate wettest specimens, reporting results for each of the five cycles as thearithmetic mean among the five wet replicates for Wet MaximumCompression Force to the nearest 1 gram-force for each cycle, Wet Energyof Compression to the nearest 0.1 N-mm for each cycle, Wet Energy Lossto the nearest 0.1 N-mm for each cycle, Wet Energy of Recovery to thenearest 0.1 N-mm for each cycle and Wet % recovery for each cycle. Ofparticular importance is the 5^(th) cycle wet energy of recovery and5^(th) cycle wet % recovery properties from this test method.

CD Cyclic Elongation to 3% Strain

The cyclic tensile and recovery response of absorbent article specimensare measured for ten cycles of load application (“elongation”) and loadremoval (“recovery”) using a universal constant rate of extension testframe. The test specimen is cycled ten times to 3% engineering strain,then back to zero engineering strain. For each cycle, stiffness, peakload, normalized energy to peak, normalized recovery energy, strain atstart of cycle, and strain at end of cycle (i.e., “permanent strain”)are calculated and reported. The intention of this method is tounderstand the ability of samples to stretch in the x-y plane as aresult of bodily forces, and then recover to their original state. Allmeasurements are performed in a laboratory maintained at 23° C.±2 C.°and 50%±2% relative humidity and test specimens are conditioned in thisenvironment for at least 2 hours prior to testing.

A suitable universal constant rate of extension test frame is the MTSAlliance interfaced to a computer running TestSuite control software(available from MTS Systems Corp, Eden Prairie, MN), or equivalent. Theuniversal test frame is equipped with a load cell for which forcesmeasured are within 1% to 99% of the limit of the cell. The fixturesused to grip the test specimen are lightweight (<80 grams), vise actionclamps with knife or serrated edge grip faces that are at least 40 mmwide. The fixtures are installed on the universal test frame and mountedsuch that they are horizontally and vertically aligned with one another.

The test specimen is prepared as follows. Obtain the test material byexcising it from an absorbent article, if necessary. When excising thetest material, do not impart any contamination or distortion to thematerial layer during the process. The test specimen is cut from an areaon the test material that is free of any residual of folds or wrinkles.The test specimen is as long as the lateral length of the article(parallel to the lateral axis of the article, or the intended lateralaxis of the article). When excising specimens from absorbent articles ofdifferent sizes and widths, the total specimen length (L_(total)) mayvary from product to product, thus the results will be normalized tocompensate for this variation. The test specimen has a width of 25.4 mmwide (parallel to the longitudinal axis, or intended longitudinal axisof the article). Specimen width (w)=25.4 mm Measure and record the totalspecimen length (L_(total)) to the nearest 0.1 mm. In like fashion, fivereplicate test specimens are prepared.

Measure the thickness (t) of the test specimen using a manually-operatedmicrometer equipped with a pressure foot capable of exerting a steadypressure of 0.1 psi+0.01 psi. The manually-operated micrometer is adead-weight type instrument with readings accurate to 0.01 mm A suitableinstrument is Mitutoyo Series 543 ID-C Digimatic, available from VWRInternational, or equivalent. The pressure foot is a flat circularmoveable face with a diameter no greater than 25.4 mm. The test specimenis supported by a horizontal flat reference platform that is larger thanand parallel to the surface of the pressure foot. Zero the micrometeragainst the horizontal flat reference platform. Place the test specimenonto the platform, centered beneath the pressure foot. The pressure footis lowered by hand with a descent rate of 3+1 mm/s until the full weightof the pressure is exerted onto the specimen. After 5 seconds elapse,the thickness is recorded as specimen thickness (t) to the nearest 0.01mm.

Prepare the universal test frame as follows. Set the initial grip togrip separation distance to a nominal gage length (L_(nominal)) that isshorter than the total specimen length and such that the specimen can begripped securely at both ends (i.e., L_(nominal)<L_(total)) Then zerothe crosshead. Program the test frame to move the grips closer togetherby an intentional slack of 1 mm to ensure no pretension force exists onthe test specimen at the onset of the test. (During this motion, thespecimen will become slack between the tensile grips.) Next, the gripswill move apart at a slack speed of 1 mm/s until the slack preload of0.05 N is exceeded. At this point, the following are true. 1) Thecrosshead position signal (mm) is defined as the specimen slack(L_(slack)) 2) The initial specimen gage length (L₀) is calculated asthe nominal gage length plus the slack L₀=L_(nominal) L_(slack), whereunits are in millimeters. 3) The crosshead extension (AL) is set to zero(0.0 mm). 4) The crosshead displacement (mm) is set to zero (0.0 mm). Atthis position the engineering strain is zero, 0.0. Engineering strain iscalculated as the change in length (AL) divided by the initial length(L₀). Engineering strain=ΔL/L₀. For one test cycle, the grips move apartat the initial speed of 1 mm/s until the engineering strain endpoint of0.03 mm/mm is exceeded, immediately followed by the grips moving towardeach other at the initial speed of 1 mm/s until the crosshead signalbecomes less than the crosshead return position of 0 mm. The test cycleis repeated until a total of 10 cycles is complete.

The test is executed by inserting the test specimen into the grips suchthat the long axis of the specimen is parallel and centered with themotion of the crosshead. Start the test and continuously collect time,force and displacement data at a data acquisition rate of 100 Hz.

Construct a graph of load (N) versus displacement for all ten cycles.For each cycle, perform the following. Record peak load to the nearest0.01 N. Calculate the energy to peak (E_(peak)) as the area under theload versus displacement curve from the cycle start to the strainendpoint of mm/mm (during the loading portion of the cycle) and recordto the nearest 0.01 N*mm Calculate the return energy (E_(return)) as thearea under the load versus displacement curve from the strain endpointof 0.03 mm/mm to the crosshead return of 0 mm (during the unloadingportion of the cycle) and record as recovery energy to the nearest 0.01N*mm Calculate the normalized energy to peak (NE_(peak)) as the energyto peak divided by the initial length, where NE_(peak)=E_(peak)/L₀, andrecord to the nearest 0.01 mN. Calculate the normalized return energy(NE_(return)) as the return energy divided by the initial length(NE_(return)=E_(return)/L₀), and record to the nearest 0.01 mN. Units ofNE_(peak) and NE_(return) are milliNewtons (mN).

Now construct a graph of engineering stress (G) versus engineeringstrain for all ten cycles, and for each cycle perform the following.Engineering stress, in units of N/mm², is the load divided by the crosssectional area of the specimen, where the cross sectional area is thespecimen width (w) multiplied by the thickness (t), 6=Load/(w*t).Determine the modulus, or slope of the stress versus strain curve for aline between the point that occurs at the minimum force and the pointthat occurs at the maximum force (during the loading portion of thecycle) and record as modulus to the nearest 0.01 N/mm Calculatestiffness by multiplying the modulus by the specimen thickness andrecord as tensile stiffness to the nearest 0.01 N/mm. The strain of thetest specimen at the beginning of the cycle is defined by the strainwhen the slack preload of 0.05 N is exceeded for that cycle (during theloading portion of the cycle), and is recorded as cycle initial strainto the nearest 0.01 mm/mm. The strain of the test specimen at the end ofthe cycle is defined by the strain when the load becomes less than thepreload of 0.05 N for that cycle (during the unloading portion of thecycle), and is recorded as permanent strain to the nearest 0.01 mm/mm.In like fashion, the overall procedure is now repeated for all fivereplicates.

The arithmetic mean among the five replicate test specimens iscalculated for each of the parameters, for each of the ten cycles, andreported as Peak Load to the nearest 0.01 N, Normalized Energy to Peakto the nearest 0.01 mN, Normalized Recovery Energy to the nearest 0.01mN, Tensile Stiffness to the nearest 0.01 N/mm, Cycle Initial Strain tothe nearest 0.01 mm/mm, and Permanent Strain to the nearest 0.01 mm/mm

Structural Bond Sites Pattern Spacing and Area Measurement Method

The spacing between the discreet structural bond sites that are used tocreate a quilt-like pattern on absorbent article samples, and theoverall area taken up by the sum of those elements in a specified regionof the sample are measured on images of the absorbent article sampleacquired using a flatbed scanner. The scanner is capable of scanning inreflectance mode at a resolution of 2400 dpi and 8 bit grayscale. Asuitable scanner is an Epson Perfection V750 Pro from Epson AmericaInc., Long Beach CA, or equivalent. The scanner is interfaced with acomputer running an image analysis program. A suitable program is ImageJv. 1.52, National Institute of Health, USA, or equivalent. The sampleimages are distance calibrated against an acquired image of a rulercertified by NIST. To enable maximum contrast, the specimen is backedwith an opaque, black background of uniform color prior to acquiring theimage. All testing is performed in a conditioned room maintained atabout 23±2° C. and about 50±2% relative humidity.

The test sample is prepared as follows. Remove the absorbent articlefrom any wrapper present. If the article is folded, gently unfold it andsmooth out any wrinkles. If wings are present, extend them but leave therelease paper intact. The test samples are conditioned at about 23° C.±2C.° and about 50%±2% relative humidity for 2 hours prior to testing.

Images are obtained as follows. The ruler is placed on the scanner bedsuch that it is oriented parallel to the sides of the scanner glass. Animage of the ruler (the calibration image) is acquired in reflectancemode at a resolution of 2400 dpi (approximately 94 pixels per mm) and in8-bit grayscale. The calibration image is saved as an uncompressed TIFFformat file. After obtaining the calibration image, the ruler is removedfrom the scanner glass and the test sample is scanned under the samescanning conditions as follows. Place the test sample onto the center ofthe scanner glass and secure, if necessary, such that it lies flat withthe body-facing surface of the sample facing the scanner's glasssurface. The sample is oriented in such a way that the entire sample iswithin the glass surface. The black background is placed on top of thespecimen, the scanner lid is closed, and a scanned image of the entiresample is acquired with the same settings as used for the calibrationimage. The sample image is saved as an uncompressed TIFF format file.

The sample image is analyzed as follows. Open the calibration image filein the image analysis program, and calibrate the image resolution usingthe imaged ruler to determine the number of pixels per millimeter. Nowopen the sample image in the image analysis program, and set thedistance scale using the image resolution determined from thecalibration image. Now visually inspect the pattern of emboss elementspresent on the sample in the image and identify the zones of the patternthat are to be analyzed. For example the absorbent article can bedivided into three equal lengths zones in the machine direction such asthe front one third zone, zone 1, the central one third zone, zone 2 andthe end one third zone, zone 3 as example. Use the image analysis toolsto draw a shape along the outer perimeter of the first discreet zone tobe analyzed. Measure the area of this first zone and record as Zone 1Total Area to the nearest 0.01 mm². Now measure the area of eachindividual, discreet emboss element that lies inside of the zone 1perimeter as follows. Draw a minimum bounding circle around anindividual emboss element such that no portion of the emboss elementlies outside of the bounding circle. Now measure the area of thebounding circle for that emboss element and record the emboss elementarea to the nearest 0.01 mm². In like fashion, measure the area of everyemboss element, including portions of emboss elements, that lie insidezone 1 and record each to the nearest 0.01 mm². Now sum the areas of allof the emboss elements inside of zone 1 and record as Zone 1 TotalEmboss Element Area to the nearest 0.01 mm². Divide the Zone 1 TotalEmboss Element Area by the Zone 1 Total Area then multiply by 100 andrecord as Zone 1% Total Area Represented by Emboss Elements. The spacingbetween each discreet emboss element inside of zone 1 is measured asfollows. Measure the distance from the center of the minimum boundingcircle drawn around a discreet emboss element inside of zone 1, asdescribed herein, to the center of the minimum bounding circle drawnaround the nearest neighboring discreet emboss element inside of zone 1,and record this distance as emboss spacing to the nearest 0.01 mm. Inlike fashion, repeat for all neighboring emboss elements inside of zone1, and record each distance to the nearest 0.01 mm Now calculate thearithmetic mean among all measured emboss spacings measured betweennearest neighbors inside of zone 1, and record as Zone 1 Emboss Spacingto the nearest 0.01 mm.

In like fashion, the entire procedure is repeated for each additionalzone containing emboss elements that is present on the test sample andlabel accordingly as Zone 2, Zone 3, etc.

Light Touch Rewet Method

Light Touch Rewet method is a quantitative measure of the mass of liquidthat emerges from an absorbent article test sample that has been dosedwith a specified volume of Artificial Menstrual Fluid (AMF; as describedherein) when a weight is applied for a specified length of time. Allmeasurements are performed in a laboratory maintained at 23° C.±2 C.°and 50%±2% relative humidity.

A syringe pump equipped with a disposable syringe is utilized to dosethe test sample. A suitable pump is the Perfusor® Compact S (availablefrom B. Braun), or equivalent, and must be able to accurately dispensethe AMF at a rate of 42 ml/min. The disposable syringe is of amplevolume (e.g., BD Plastipak 20 mL) and is connected to flexible tubingthat has an inner diameter of 3/16″ (e.g., Original Perfusor® Line,available from Braun, or equivalent). The AMF is prepared, as describedherein, and is brought to room temperature (23° C.±2 C.°) prior to usingfor this test. Prior to the commencement of the measurement, the syringeis filled with AMF and the flexible tubing is primed with the liquid,and the dispensing rate (42 ml/min) and dosing volume (4.0 mL+0.05 mL)are verified according to the manufacturer's instructions. The flexibletubing is then mounted such that it is oriented vertically above thetest sample, and the distance between the tip of the tubing and thesurface of the test sample is 19 mm. To note, the AMF must be removedfrom the syringe and thoroughly mixed every 15 minutes.

The rewet weight assembly consists of an acrylic plate and a stainlesssteel weight. The acrylic plate has dimensions of 65 mm by 80 mm with athickness of about 5 mm. The stainless steel weight along with theacrylic plate have a combined mass of 2 pounds (907.19 g), to impart apressure of 0.25 psi beneath the surface of the acrylic plate.

For each test sample, five sheets of filter paper with dimensions of 4inch by 4 inch are used as the rewet substrate. The filter paper isconditioned at 23° C.±2 C.° and 50%±2% relative humidity for at least 2hours prior to testing. A suitable filter paper has a basis weight ofabout 139 gsm, a thickness of about 700 microns with an absorption rateof about 1.7 seconds, and is available from Ahlstrom-Munksjo NorthAmerica LLC, Alpharetta, GA VWR International as Ahlstrom grade 989, orequivalent.

Prepare the test sample as follows. The test samples are conditioned at23° C.±2 C.° and 50%±2% relative humidity for at least 2 hours prior totesting. Test samples are removed from all packaging using care not topress down or pull on the products while handling. Lay the test sampleon a horizontally rigid flat surface and gently smooth out any folds.Determine the test location as follows. For symmetrical samples (i.e.,the front of the sample is the same shape and size as the back of thesample when divided laterally along the midpoint of the longitudinalaxis of the sample), the test location is the intersection of themidpoints of the longitudinal axis and lateral axis of the sample. Forasymmetrical samples (i.e., the front of the sample is not the sameshape and size as the back of the sample when divided laterally alongthe midpoint of the longitudinal axis of the sample), the test locationis the intersection of the midpoint of the longitudinal axis of thesample and a lateral axis positioned at the midpoint of the sample'swings. A total of three test samples are prepared.

Place the test sample on a horizontally flat rigid surface, with thepreviously identified test location centered directly below the tip ofthe flexible tubing. Adjust the height of the tubing such that it is19.0 mm above the surface of the test sample. Start the pump to dispense4.0 mL+0.05 mL of AMF at a rate of 42 ml/min. As soon as the AMF hasbeen fully dispensed, start a 10 minute timer. Now obtain the mass of 5sheets of the filter paper and record as dry mass to the nearest grams.When 10 minutes have elapsed, place the five sheets of pre-weighedfilter papers onto the test sample, centering the stack over the dosinglocation. Now place the acrylic plate centered over the top of thefilter papers such that the long side of the plate is parallel with thelongitudinal axis of the test sample. Now carefully lower the stainlesssteel weight centered over the acrylic plate and immediately start a 30second timer. After 30 seconds have elapsed, gently remove the rewetweight and acrylic plate and set aside. Obtain the mass of the fivesheets of filter paper and record as wet mass to the nearest 0.001grams. Subtract the dry mass from the wet mass of the filter papers, andrecord as rewet to the nearest 0.001 grams. Wipe off any residual testliquid from the bottom face of the acrylic plate prior to testing thenext sample. In like fashion, repeat for a total of three replicate testsamples.

The arithmetic mean of the rewet among the three replicate test samplesis calculated and reported as the ‘Light Touch Rewet’ to the nearest0.001 g.

Artificial Menstrual Fluid (AMF) Preparation

The Artificial Menstrual Fluid (AMF) is composed of a mixture ofdefibrinated sheep blood, a phosphate buffered saline solution and amucous component. The AMF is prepared such that it has a viscositybetween 7.15 to 8.65 centistokes at 23° C.

Viscosity of the AMF is performed using a low viscosity rotaryviscometer (a suitable instrument is the Cannon LV-2020 RotaryViscometer with UL adapter, Cannon Instrument Co., State College, PA, orequivalent). The appropriate size spindle for the viscosity range isselected, and instrument is operated and calibrated as per themanufacturer. Measurements are taken at 23° C.±1 C.° and at 60 rpm.Results are reported to the nearest 0.01 centistokes.

Reagents needed for the AMF preparation include: defibrinated sheepblood with a packed cell volume of 38% or greater (collected understerile conditions, available from Cleveland Scientific, Inc., Bath, OH,or equivalent), gastric mucin with a viscosity target of 3-4 centistokeswhen prepared as a 2% aqueous solution (crude form, sterilized,available from American Laboratories, Inc., Omaha, NE, or equivalent),10% v/v lactic acid aqueous solution, 10% w/v potassium hydroxideaqueous solution, sodium phosphate dibasic anhydrous (reagent grade),sodium chloride (reagent grade), sodium phosphate monobasic monohydrate(reagent grade) and distilled water, each available from VWRInternational or equivalent source.

The phosphate buffered saline solution consists of two individuallyprepared solutions (Solution A and Solution B). To prepare 1 L ofSolution A, add 1.38±0.005 g of sodium phosphate monobasic monohydrateand 8.50±0.005 g of sodium chloride to a 1000 mL volumetric flask andadd distilled water to volume. Mix thoroughly. To prepare 1 L ofSolution B, add 1.42±0.005 g of sodium phosphate dibasic anhydrous and8.50±0.005 g of sodium chloride to a 1000 mL volumetric flask and adddistilled water to volume. Mix thoroughly. To prepare the phosphatebuffered saline solution, add 450±10 mL of Solution B to a 1000 mLbeaker and stir at low speed on a stir plate. Insert a calibrated pHprobe (accurate to 0.1) into the beaker of Solution B and add enoughSolution A, while stirring, to bring the pH to 7.2±0.1.

The mucous component is a mixture of the phosphate buffered salinesolution, potassium hydroxide aqueous solution, gastric mucin and lacticacid aqueous solution. The amount of gastric mucin added to the mucouscomponent directly affects the final viscosity of the prepared AMF. Todetermine the amount of gastric mucin needed to achieve AMF within thetarget viscosity range (7.15-8.65 centistokes at 23° C.) prepare 3batches of AMF with varying amounts of gastric mucin in the mucouscomponent, and then interpolate the exact amount needed from aconcentration versus viscosity curve with a least squares linear fitthrough the three points. A successful range of gastric mucin is usuallybetween 38 to 50 grams.

To prepare about 500 mL of the mucous component, add 460±10 mL of thepreviously prepared phosphate buffered saline solution and 7.5±0.5 mL ofthe 10% w/v potassium hydroxide aqueous solution to a 1000 mL heavy dutyglass beaker. Place this beaker onto a stirring hot plate and whilestirring, bring the temperature to 45° C.±5 C°. Weigh the pre-determinedamount of gastric mucin (±0.50 g) and slowly sprinkle it, withoutclumping, into the previously prepared liquid that has been brought to45° C. Cover the beaker and continue mixing. Over a period of 15 minutesbring the temperature of this mixture to above 50° C. but not to exceed80° C. Continue heating with gentle stirring for 2.5 hours whilemaintaining this temperature range. After the 2.5 hours has elapsed,remove the beaker from the hot plate and cool to below 40° C. Next add1.8±mL of the 10% v/v lactic acid aqueous solution and mix thoroughly.Autoclave the mucous component mixture at 121° C. for 15 minutes andallow 5 minutes for cool down. Remove the mixture of mucous componentfrom the autoclave and stir until the temperature reaches 23° C.±1 C°.

Allow the temperature of the sheep blood and mucous component to come to23° C.±1 C°. Using a 500 mL graduated cylinder, measure the volume ofthe entire batch of the previously prepared mucous component and add itto a 1200 mL beaker. Add an equal volume of sheep blood to the beakerand mix thoroughly. Using the viscosity method previously described,ensure the viscosity of the AMF is between 7.15-8.65 centistokes. If notthe batch is disposed and another batch is made adjusting the mucouscomponent as appropriate.

The qualified AMF should be refrigerated at 4° C. unless intended forimmediate use. AMF may be stored in an air-tight container at 4° C. forup to 48 hours after preparation. Prior to testing, the AMF must bebrought to 23° C.±1 C°. Any unused portion is discarded after testing iscomplete.

Examples/Data

The following data and examples, including comparative examples, areprovided to help illustrate the upper and lower nonwoven layers,absorbent core structures and/or absorbent articles described herein.The exemplified structures are given solely for the purpose ofillustration and are not to be construed as limitations of the presentdisclosure, as many variations thereof are possible without departingfrom the spirit and scope of the invention.

Nonwoven Material Test

Nonwoven layer materials are tested to assess the ability of thenonwoven material to strain (elongate) with a balanced stretch and torecover to their original state (simulating in-use physicaldeformation). Samples F-H are comparative examples. The test isperformed according to the CD Cyclic Elongation to 3% Strain Method andthe Strain to Break Method described herein. The results are shown inTable 1.

TABLE 1 Nonwoven Materials tested in the CD Cyclic Elongation to 3%Strain Method and the Strain to Break Method Tensile Permanent % StrainNonwoven Fiber Stiffness Strain to Break Sample Material CompositionN/mm mm/mm % A 40 gsm BiCo (PE/ 0.30 0.0060 >10% Carded PET)-60% 2Resilient DTex/40% 4 Nonwoven¹ DTex Blend B 55 gsm 30% 10 DTex 1.570.0064 >10% Resilient HS-PET; Spunlace 1² 20% 1.3 DTex Rayon; 50% 2.2DTex BiCo (PE/PET) C 50 gsm 20% 1.3 1.50 0.0054 >10% Resilient DTexRayon; Spunlace 6³ 20% 3.3 DTex tri-lobal Rayon; 60% 5.8 DTex PE/PET D24 gsm 100% 2 DTex 0.16 0.0160 >10% Carded BiCo Nonwoven⁴ (PE/PET) E 55gsm 40% 1.7 DTex/ 0.31 0.0127 >10% Resilient 38 mm Rayon; Spunlace 5⁵40% 2.2 DTex PET; 20% 10 DTex HS PET F 18 gsm 100% 2.0 0.24 0.0096 >10%Spunbond DTex PP Nonwoven⁶ G 25 gsm 100% 2.0 0.37 0.0093 >10% SpunbondDtex PP Nonwoven⁷ H 17 gsm 100% Cellulose 1.72 0.0137  <5% Tissue⁸¹Available as ATB Z87G-40 from Xiamen Yanjan New Material Co. (China)²Available as Sawasoft ® 53FC041001 from Sandler GmbH (Germany)³Available as Sawasoft ® 553FC041005 (option 82) from Sandler GmbH(Germany) ⁴Available as Aura 20 from Xiamen Yanjan New Material Co.(China) ⁵Available as S25000541R01 from Jacob Holms Industries (Germany)⁶Available as PFNZN 18G BICO8020 PHI 6 from dPFNonwovens Czech S.R.O(Czech Republic) ⁷Available as PEGZN25 BICO7030 Phobic from dPFNonwovensCzech S.R.O (Czech Republic) ⁸Available as 3028 from DunnPaper (USA)

It is found that suitable nonwoven layer materials strain (elongate)with a balanced stretch vs. recovery behavior. If the nonwoven layermaterial elongates plastically (i.e., stretches but does not recover) asthe fluff/AGM matrix in the inner core layer elongates, there will beinsufficient recovery energy to return to the initial, pre-stretchedstate and the nonwoven layer material will become permanently strained(stretched). The upper nonwoven layers of the present disclosure canhave a Permanent Strain value of less than about 0.013. At the sametime, if the nonwoven layer material is strained aggressively, forexample greater than 5%, the nonwoven layer material needs to retain itsintegrity and not tear or break (see, for example, Sample H which tearsand has a Strain to Break of less than 5%). Nonwoven layers of thepresent disclosure can have a Strain to Break of greater than about 10%.

The nonwoven layer materials described above are also tested to assessthe ability of nonwoven materials to bend and deform and to recover totheir original state. The test is performed according to the Wet and DryCD Ultra Sensitive 3 Point Bending Method described herein. The resultsare shown in Table 2.

TABLE 2 Nonwoven Materials Tested in the Wet and Dry CD Ultra Sensitive3 Point Bending Method Dry Bending Dry Recovery Dry Peak Load EnergyEnergy Sample N N*mm N*mm A 0.07 0.219 0.092 B 0.38 1.015 0.291 C 0.260.595 0.201 D 0.09 0.176 0.036 E 0.03 0.059 0.032 F 0.01 0.0216 0.005 G0.03 0.0624 0.019 H 0.04 0.0734 0.031

During walking, an absorbent article is compressed and bent side-to-sidein a cyclic pattern as the gap between her legs narrows and then expandswith her leg motions. Without being limited by theory, it is believedthat a nonwoven layer material having a Dry Bending Energy of less thanabout 2 N*mm will allow this bending compression to occur readily yetwill not be so stiff as to hinder the bending compression. At the sametime, following the bending compression, the nonwoven layer needs to beable to sustain sufficient dry recovery energy to return the nonwovenlayer and the fluff/AGM matrix in the inner core layer back to itsinitial, pre-bent state. The upper nonwoven layers of the presentdisclosure can have a Dry Recovery Energy value of greater than about0.03 N*mm.

Samples A-E exhibit a Dry Peak Load of from 0.03 N to 0.38 N and a DryRecovery Energy of from 0.032 to 0.092 N*mm, demonstrating that thesematerials readily bend and have sufficient dry recovery energy torecover their initial, pre-bent state. Samples F and G, which arecomparative examples, exhibit a Dry Peak Load of 0.01 N and 0.03 N,respectively, and a Dry Recovery Energy of 0.005 N*mm and 0.019 N*mm,respectively, demonstrating that while these materials readily bend,they do not have sufficient recovery energy to recover their initial,pre-bent state after compression. Sample H (comparative example)exhibits a Dry Peak Load of 0.04 N and a Dry Recovery Energy of 0.031N*mm. However, it is found that Sample H tears when it becomes wet,making it insufficient to function as an upper and/or lower nonwovenlayer of the present disclosure.

Without being limited by theory, it is believed that nonwoven layermaterials comprising thick fibers (from about 2.0 Dtex to about 10 Dtex)that are arranged within a network structure are able to carry themechanical load within the fiber network and return the absorbent corestructure and/or absorbent article to its initial shape followingbending compression. Samples F and G comprise relatively fine fibers(less than about 2.0 Dtex), while Samples A-E comprise fiber blendshaving a fiber thickness of from about 2.2 Dtex to about 10 Dtex.

Absorbent Core Structure Test

Absorbent cores structures are tested to assess the ability of theabsorbent core structure to compress (simulating the compressionsexperienced between a wearer's legs) and to recover to their originalstate. Examples 1-3 in Table 3 illustrate absorbent core structuresdescribed herein. Comp. Ex. A-C are comparative examples. A descriptionof Ex. 1-3 and Comp. Ex. A-C are listed in Table 3. The absorbent corestructures are prepared as described hereafter. The absorbent corestructures are evaluated according to the Wet and Dry BunchedCompression Method as described herein. The results are shown in Table4.

TABLE 3 Absorbent Core Structures Upper Lower Nonwoven Inner NonwovenExample Layer Core Layer Layer Ex. 1 40 gsm Carded 175 gsm Fluff¹⁰/ 18gsm Resilient  70 gsm AGM⁹ Spunbond Nonwoven¹ Nonwoven⁶ Ex. 2   55 gsmResilient 175 gsm Fluff¹⁰/ 18 gsm Spunlace 5⁵  70 gsm AGM⁹ SpunbondNonwoven⁶ Ex. 3   50 gsm Resilient 175 gsm Fluff¹⁰/ 40 gsm CardedSpunlace 6³  70 gsm AGM⁹ Nonwoven¹ Comp. 24 gsm Carded 175 gsm Fluff¹⁰/10 gsm SMS Ex. A Nonwoven⁴  70 gsm AGM⁹ Nonwoven¹¹ Comp. 17 gsm Tissue⁸175 gsm Fluff¹⁰/ 17 gsm Ex. B  70 gsm AGM⁹ Tissue⁸ Comp. 17 gsm Tissue⁸175 gsm Fluff¹⁰/ 17 gsm Ex. C (10 × 10 bonding)  70 gsm AGM⁹ Tissue⁸¹Available as ATB Z87G-40 from Xiamen Yanjan New Material Co. (China)³Available as Sawasoft ® 553FC041005 (option 82) from Sandler GmbH(Germany) ⁴Available as Aura 20 from Xiamen Yanjan New Material Co.(China) ⁵Available as S25000541R01 from Jacob Holms Industries (Germany)⁶Available as PFNZN 18G BICO8020 PHI 6 from dPFNonwovens Czech S.R.O(Czech Republic) ⁸Available as 3028 from DunnPaper (USA) ⁹Available asFavor SXM9745 from Evonik (Germany) ¹⁰Available as Item 9E3-COOSABSORB Sfrom Resolute Alabama (USA) ¹¹Available as Article 4004416 (MR 3585374)from Fitesa (Germany)

The absorbent core structures listed in Table 3 are produced as detailedwithin the specification. Specifically, the upper nonwoven layer isfirst introduced onto the forming drum within the laydown section, andunder vacuum it is drawn into the 3 dimensional pocket shape. Ahomogeneous stream of the fluff (cellulose) and AGM material isdeposited onto the upper nonwoven layer directly within the formingstation. Prior to entering the forming station, the upper nonwoven iscoated with a spray adhesive (Technomelt DM 9036U available from Henkel,(Germany), 6 gsm continuous meltblown spirals, 50 mm wide) to provide astronger connection of the fluff (cellulose) and AGM to the uppernonwoven layer without hindering the flow of liquid into the fluff/AGMmatrix. On exiting the laydown section, the lower nonwoven web iscombined with the nonwoven carrying the homogeneous blend of fluff/AGM.This lower nonwoven is precoated with adhesive (Technomelt DM 9036Uavailable from Henkel (Germany)) to enable a perimeter seal (10 gsmmeltblown spirals, 20 mm wide on the sides) and in the center a 6 gsm,50 mm wide continuous meltblown spiral adhesive (Technomelt DM 9036Uavailable from Henkel (Germany)) is applied to better integrate thefluff/AGM matrix.

Ex. 1 through 3 and Comp. Ex. A and B also have the structural bondsshown in FIG. 8 with the profile shown in FIG. 9 . Ex. 1-3 and Comp. Ex.A-B have a structural bond spacing of 32 mm×16 mm, thereby occupying atotal structural bond site area of 1.38% of the total area of theabsorbent core structure. Comp Ex. C is identical to Comp. Ex. B exceptthe structural bond spacing is 10 mm×10 mm, thereby occupying a totalstructural bond site area of 6.28% of the total area of the absorbentcore structure. The structural bonds are applied with a heated aluminumdie to create an emboss pattern within a heated hydraulic press. Thestructural bond embosser plate has protrusions of an area of 3.55 mm²and about 1 mm in height as shown in FIG. 8 with the profile shown inFIG. 9 . The structural bonds are spaced according to the dimensions ofseparation described above. The structural bond embosser plate is heatedto 120° C. and set to a compression pressure of 170 kPa. The absorbentarticle is placed and orientated underneath the heated embosser plate onthe hydraulic press bottom plate and a sheet of thin Teflon™ film isplaced over the sample prior to embossing to avoid melting of thetopsheet fibers. The hydraulic press is activated and compresses thesample for a dwell time of 1.7 seconds to create the structural bondpattern.

Ex. 1-3 and Comp. Ex. A-C also have flex bond channel regions appliedwith the pattern shown in FIG. 2C. The flex bond channel regions areapplied with a heated aluminum die to create an emboss pattern within aheated hydraulic press. The flex bond channel embosser plate hasprotrusions spaced about 1.5 mm apart and are about 3 mm long and about1.5 mm wide. The bond channel embosser plate is heated to 120° C. andset to a compression pressure of 200 kPa. The absorbent article isplaced and orientated underneath the heated embosser plate on thehydraulic press bottom plate and a sheet of thin Teflon™ film is placedover the sample prior to embossing to avoid melting of the topsheetfibers. The hydraulic press is activated and compresses the sample for adwell time of 1.7 seconds to create the emboss pattern.

TABLE 4 Absorbent Core Structures Measured in the Wet and Dry BunchedCompression Method Wet and Dry Bunched Compression Method 5^(th) CycleWet 5^(th) Cycle Wet Maximum Energy of Compression Force RecoveryExample (gf) (N*mm) Ex. 1 208 1.30 Ex. 2 207 1.07 Ex. 3 213 1.76 Comp.Ex. A 136 0.26 Comp. Ex. B 129 0.59 Comp. Ex. C 86 0.32

It is found that absorbent core structures comprising nonwoven layermaterials that have sufficient resiliency and recovery energy are ableto recover to the original, pre-compression absorbent core structureshape. Ex. 1-3 exhibit a 5^(th) Cycle Wet Energy of Recovery of greaterthan 1.0 N*mm and a 5^(th) Cycle Wet Maximum Compression Force of from207 gf to 213 gf. These structures exhibit a low force to compress (lessresistance so it feels soft and flexible), yet are still able to recovertheir shape as the structure is compressed and released in a cyclicfashion. However, Comp. Ex. A-C exhibit a 5^(th) Cycle Wet Energy ofRecovery of from 0.26 to 0.59 N*mm Without sufficient recovery energyafter five cycles of compression, Comp. Ex. A-C remain in a compressed,bunched state with insufficient force (stored energy) to recover itsoriginal, pre-compression shape.

Absorbent core structures and/or absorbent articles of the presentdisclosure can have a 5th Cycle Wet Energy of Recovery of greater thanabout 1.0 N*mm, or from about 1.0 to about 3.5 N*mm Absorbent corestructures and/or absorbent articles of the present disclosure can havea 5^(th) Cycle Wet Maximum Compression Force of greater than about 150gf, preferably greater than about 200 gf, or from about 150 gf to about225 gf.

It is found that while an individual nonwoven material may havesufficient % Strain to Break in the Strain to Break Method, oncecombined into an absorbent core structure, the nonwoven material may notbe capable of providing sufficient recovery energy for the fullabsorbent core structure (such as, for example in Comp. Ex. A) to returnto its original, pre-compression shape. For instance, in Comp. Ex. A,the basis weight and thickness of the fibers of the upper nonwovenmaterial when combined with the thin lower nonwoven material provides a5^(th) Cycle Wet Energy of Recovery of less than 1.0 N*mm.

Finished Product Test

Absorbent articles are tested to assess the ability of a wrappedabsorbent core structure to compress (simulating the compressionsexperienced between a wearer's legs) and to recover to their originalstate. Ex. 4-7 illustrate absorbent articles described herein. Comp. Ex.D and E are comparative examples. Comp. Ex. F-L are in-market finishedproducts. A description of Ex. 4-7 and Comp. Ex. D-E are listed in Table5a. A description of Comp. Ex. F-L is listed in Tables 5b and 5c. Ex.4-7 and Comp. Ex. D and E are prepared as described hereafter. Theabsorbent articles in Table 5a and 5b are evaluated according to the Wetand Dry CD and MD 3 Point Bend Method, the Wet and Dry BunchedCompression Method, and the Light Touch Rewet Method as describedherein. The results are shown in in Table 6.

TABLE 5a Absorbent Article Description Absorbent core structure UpperLower Nonwoven Inner Core Nonwoven Example Topsheet Layer Layer LayerEx. 4 Nonwoven 40 gsm 175 gsm 18 gsm SG¹² Carded Fluff¹⁰/ SpunbondResilient 70 gsm AGM⁹ Nonwoven⁶ Nonwoven¹ Ex. 5 Nonwoven 55 gsm 175 gsm18 gsm SG¹² Resilient Fluff¹⁰/ Spunbond Spunlace 5⁵ 70 gsm AGM⁹Nonwoven⁶ Ex. 6 Nonwoven 50 gsm 175 gsm 18 gsm SG¹² Resilient Fluff¹⁰/Spunbond Spunlace 6³ 70 gsm AGM⁹ Nonwoven⁶ Ex. 7 Nonwoven 55 gsm 175 gsm18 gsm SG¹² Resilient Fluff¹⁰/ Spunbond Spunlace 1² 70 gsm AGM⁹Nonwoven⁶ Comp. Nonwoven 24 gsm 175 gsm 18 gsm Ex. D SG¹² CardedFluff¹⁰/ Spunbond Nonwoven⁴ 70 gsm AGM⁹ Nonwoven⁶ Comp. Nonwoven 17 gsm175 gsm Fluff¹⁰/ 17 gsm Ex. E SG¹² Tissue⁸ 70 gsm AGM⁹ Tissue⁸¹Available as ATB Z87G-40 from Xiamen Yanjan New Material Co. (China)²Available as Sawasoft ® 53FC041001 from Sandler GmbH (Germany)³Available as Sawasoft ® 553FC041005 (option 82) from Sandler GmbH(Germany) ⁴Available as Aura 20 from Xiamen Yanjan New Material Co.(China) ⁵Available as S25000541R01 from Jacob Holms Industries (Germany)⁶Available as PFNZN 18G BICO8020 PHI 6 from dPFNonwovens Czech S.R.O(Czech Republic) ⁸Available as 3028 from DunnPaper (USA) ⁹Available asFavor SXM9745 from Evonik (Germany) ¹⁰Available as Item 9E3-COOSABSORB Sfrom Resolute Alabama (USA) ¹²The nonwoven topsheet “Nonwoven SG” is anonwoven web according to U.S. Patent Publication No. 2019/0380887.

TABLE 5b In-Market Finished Products: Example In-Market Product SizeWhere Produced Comp. Ex. F Always Ultra Size 2 Canada Comp. Ex. GStayfree Ultra Size Long USA Comp. Ex. H U by K Size Long USA (KotexSecurity) Comp. Ex. I Body Form Size Long UK Comp. Ex. J Kao Laurier FSize Long Japan Comp. Ex. K Unicharm Sofy Naked Size regular Japan FeelComp. Ex. L Always Infinity Size 2 Canada

TABLE 5c Materials Found in the In-Market Products (Comp. Ex. F to L)First In-Market Acquisition Fluid Storage Products Topsheet Layer LayerOther Comp. Ex. F Formed 55 gsm 163 gsm Airlaid n/a Film Spunlace Comp.Ex. G Spunbond Airlaid Fluff/AGM n/a Nonwoven Secondary core Topsheetdensified Comp. Ex. H Spunbond Airlaid Tissue wrapped AdditionalNonwoven Secondary Fluff/AGM cellulose oval Topsheet core-densifiedelement under topsheet Comp. Ex. I Spunbond Airlaid Fluff/AGM n/aNonwoven Secondary core-densified Topsheet Comp. Ex. J Carded CardedTissue wrapped n/a Nonwoven Nonwoven fluff/AGM core Comp. Ex. K CardedCarded Tissue wrapped n/a Nonwoven Nonwoven fluff/AGM core Comp. Ex. LSpunbond High Internal High Internal n/a Nonwoven Phase Foam Phase Foam

Ex. 4 through 7 and Comp. Ex. D and E include structures as detailed forthe Ex. 1 through 3 in Table 3 with the same adhesive designs and same32 mm×16 mm structural bond pattern (a total structural bond site areaof 1.38% of the total area of the absorbent core structure) in theabsorbent core structure. Additionally, the absorbent articles include anonwoven topsheet web as detailed in US Patent Publication No.2019/0380887 bonded to the absorbent core structure with a sprayadhesive application (Technomelt DM 9036U available from Henkel(Germany), 3 gsm continuous meltblown spirals, 50 mm wide, 150 mm long).In addition, a 12 gsm polypropylene backsheet is bonded to theoutward-facing surface of the lower nonwoven with a spray adhesiveapplication (Technomelt DM 9036U available from Henkel (Germany), 3 gsmcontinuous meltblown spirals, 50 mm wide, 150 mm long).

Ex. 4-7 and Comp. Ex. D and E also have the structural bonds shown inFIG. 8 with the profile shown in FIG. 9 . The structural bonds areapplied with a heated aluminum die to create an emboss pattern within aheated hydraulic press. The structural bond embosser plate hasprotrusions of an area of 3.55 mm² and about 1 mm in height as shown inFIG. 8 with the profile shown in FIG. 9 . The structural bonds arespaced according to the dimensions of separation described above. Thestructural bond embosser plate is heated to 120° C. and set to acompression pressure of 170 kPa. The absorbent article is placed andorientated underneath the heated embosser plate on the hydraulic pressbottom plate and a sheet of thin Teflon™ film is placed over the sampleprior to embossing to avoid melting of the topsheet fibers. Thehydraulic press is activated and compresses the sample for a dwell timeof 1.7 seconds to create the structural bond pattern.

Prior to bonding the backsheet, flex bond channel regions are applied toEx. 4-7 and Comp. Ex. D and E with the pattern shown in FIG. 7 . Theflex bond channel regions are applied with a heated aluminum die tocreate an emboss pattern within a heated hydraulic press. The channelembosser plate has protrusions spaced about 1.5 mm apart and are about 3mm long and about 1.5 mm wide. The bond channel embosser plate is heatedto 120° C. and set to a compression pressure of 200 kPa. The absorbentarticle is placed and orientated underneath the heated embosser plate onthe hydraulic press bottom plate and a sheet of thin Teflon™ film isplaced over the sample prior to embossing to avoid melting of thetopsheet fibers. The hydraulic press is activated and compresses thesample for a dwell time of 1.7 seconds to create the emboss pattern.

TABLE 6 Absorbent Articles and In-Market Finished Products Tested in theWet and Dry CD and MD 3 Point Bend Method, the Wet and Dry BunchedCompression Method, and the Light Touch Rewet Method Wet & Dry CD & MD 3Wet and Dry Bunched Light Touch Point Bend Method Compression MethodRewet CD Dry 5^(th) Cycle Wet 5^(th) Method Dry CD Dry Bending Energy ofCycle Wet Light Touch Caliper Modulus Stiffness Recovery % RecoveryRewet Example (mm) (N/mm²) (N · mm²) (N · mm) % (g) Ex. 4 2.61 0.21 14.92.76 36 0.070 Ex. 5 3.35 0.09 13.5 1.68 29 0.075 Ex. 6 3.53 0.07 13.01.50 31 0.047 Ex. 7 2.74 0.22 18.7 3.15 34 0.10 Comp. Ex. D 3.76 0.0613.0 1.70 27 0.17 Comp. Ex. E 3.44 0.08 9.1 1.29 24 0.31 Comp. Ex. F2.13 1.39 54.5 0.7 43 n/a Comp. Ex. G 3.05 0.41 47.5 3.1 24 n/a Comp.Ex. H 2.66 0.43 30.8 2.0 28 n/a Comp. Ex. I 2.62 0.52 39.4 3.0 27 n/aComp. Ex. J 4.84 0.10 49.4 4.8 35 n/a Comp. Ex. K 3.11 0.25 30.6 1.3 26n/a Comp. Ex. L 2.80 0.30 29 2.5 73 n/a

It is believed that in order to provide high bodily conformability, theabsorbent article of the present disclosure can exhibit a low CD DryBending Stiffness (i.e., high flexibility) of from about 10 to about 30N·mm², or from about 10 to about 25 N·mm². Also, it is believed that inorder to provide an absorbent article that can compress with bodilymotion and recover to its original, pre-compressed state against theuser's body, the absorbent article of the present disclosure can have a5^(th) Cycle Wet Energy of Recovery of from about 1.0 to about 3.5 N·mmand/or a 5^(th) Cycle Wet % Recovery of from about 29% to about 40%.Absorbent articles of the present disclosure can also maintain goodfluid handling that delivers a low light touch rewet of from about 0 toabout 0.15 g.

Ex. 4-7 exhibit a CD Dry Bending Stiffness of from 13.0 to 18.7 N mm²and a 5^(th) Cycle Wet % Recovery in the Wet and Dry Bunched CompressionMethod of from 29 to 36%, demonstrating that these structures will beable to sustain their shape in use. Comp. Ex. D and E exhibit a CD DryBending Stiffness of 9.1 and 13.0 N mm², respectively. However, Comp.Ex. D and E exhibit a 5^(th) Cycle Wet % Recovery in the Wet and DryBunched Compression Method that is less than 29%, demonstrating thatthese structures will be unable to sustain their shape in use and willremain bunched. Comp. Ex. F-L, which are in-market finished products,exhibit a CD Dry Bending Stiffness of 29 to 47.5 N·mm², demonstratingthat the structures are less flexible and less able to conform.

Without being limited by theory, it is believed that in order to sustaina comfortable shape recovery after compression, sufficient recoveryenergy is needed to push the absorbent article on the panty back to itspre-compression shape. At the same time, the absorbent article (via theabsorbent core structure) needs to recover along the same path as thecompression to return to its pre-compression location. If the 5^(th)Cycle Wet Energy of Recovery is less than about 1.0 N·mm the absorbentarticle may not have the recovery energy needed to recover its shape. Ifthe 5^(th) Cycle Wet Energy of Recovery value is too high, the recoverymay be too forceful, leaving the wearer to feel like the absorbentarticle is not staying in place. If the 5th Cycle Wet % Recovery valueis low (less than about 29%), the absorbent article may not return toits pre-compression shape and may remain deformed and bunched. If the5^(th) Cycle Wet % Recovery value is excessively high (greater thanabout 40%), it suggests that the absorbent article may recover toostrongly to the flat shape when it is first applied to the wearer'spanty as opposed to the shape against her body.

Structural Bond Test

Absorbent cores structures are tested to assess the impact of structuralbond areas on flexibility and bending stiffness. Ex. 8 does not featureany structural bonds within the absorbent core structure. Ex. 9 and Ex.10 have the structural bonds shown in FIG. 8 with the profile shown inFIG. 9 . Ex. 8-10 are prepared as described hereafter. Results of theWet and Dry MD 3 Point Bend Method are shown in Table 7.

TABLE 7 Absorbent Core Structures according to the invention withdifferent Structural Bond Areas Tested in the Wet and Dry CD and MD 3Point Bend Method. MD Dry Upper Inner Lower Structural Bending NonwovenCore Nonwoven Bond Stiffness Example Layer Layer Layer Spacing (N · mm²)Ex. 8 50 gsm 175 gsm 10 gsm Non- 9.8 Resilient Fluff¹⁰/ SMS StructuralSpunlace  70 gsm Nonwoven¹³ Bonds 6³ AGM⁹ Ex. 9 50 gsm 175 gsm 10 gsm 32mm × 19.2 Resilient Fluff¹⁰/ SMS 16 mm Spunlace  70 gsm Nonwoven¹³ 6³AGM⁹ Ex. 10 50 gsm 175 gsm 10 gsm 16 mm × 29.6 Resilient Fluff¹⁰/ SMS 16mm Spunlace  70 gsm Nonwoven¹³ 6³ AGM⁹ ³Available as Sawasoft ®553FC041005 (option 82) from Sandler GmbH (Germany) ⁹Available as FavorSXM9745 from Evonik (Germany) ¹⁰Available as Item 9E3-COOSABSORB S fromResolute Alabama (USA) ¹³Available as 10 SMS PHILIC from UnionIndustries SpA. (Italy)

Table 7 demonstrates the impact of the total structural bond site areaand spacing amount. The asymmetric structural bond shape as shown inFIG. 8 and the profile as shown in FIG. 9 has a maximum area of 3.55mm². It is found that the MD Dry Bending Stiffness increases with thestructural bond area. Ex. 8, which has non-structural bonds, exhibits anMD Dry Bending Stiffness of 9.8 N·mm². Ex. 9, which has a structuralbond spacing of 32 mm×16 mm (a total structural bond site area of 1.38%of the total area of the absorbent core structure), exhibits an MD DryBending Stiffness of 19.2 N·mm². Ex. 10, which has a structural bondspacing of 16 mm×16 mm (a total structural bond site area of 3.96% ofthe total area of the absorbent core structure), exhibits an MD DryBending Stiffness of 29.6 N·mm². It is believed that in order tomaintain a flexible and conformable absorbent core structure and/or anabsorbent article in the front to back (MD) direction of wearing, theabsorbent core structure and/or absorbent article can have an MD DryBending Stiffness of from about 10 to about 30 N·mm².

The absorbent core structures listed in Table 7 are produced as detailedwithin the specification. Specifically, the 50 gsm Resilient Spunlace 6upper nonwoven is first introduced onto the forming drum within thelaydown section, and under vacuum, it is drawn into the 3 dimensionalpocket shape. A homogeneous stream of the fluff (cellulose) and AGMmaterial is deposited onto the upper nonwoven material directly withinthe forming station. Prior to entering the forming station, the uppernonwoven is coated with a spray adhesive (Technomelt DM 9036U availablefrom Henkel (Germany), 6 gsm continuous meltblown spirals, 50 mm wide)to provide a stronger connection of the fluff (cellulose) and AGM to theupper nonwoven layer without hindering the flow of liquid into thefluff/AGM mass. On exiting the laydown section, the 10 gsm SMS lowernonwoven web is combined with the nonwoven carrying the homogeneousblend of fluff (cellulose) and AGM layer. This lower nonwoven isprecoated with adhesive (Technomelt DM 9036U available from Henkel(Germany)) to enable a perimeter seal (10 gsm meltblown spirals, 20 mmwide on the sides) and in the center a 6 gsm, 50 mm wide continuousmeltblown spiral adhesive is applied to better integrate the fluff/AGMmass. Structural bonds as shown in FIG. 8 with the profile shown in FIG.9 are applied to Ex. 9 and 10. The structural bonds of Ex. 9 have aspacing of 32 mm×16 mm, thereby occupying a total structural bond sitearea of 1.38% of the total area of the absorbent core structure. Thestructural bonds of Ex. 10 have a spacing of 16 mm×16 mm, therebyoccupying a total structural bond site area of 3.96% of the total areaof the absorbent core structure with this structural bond profile. Thetotal area of the absorbent core structure is measured according to theStructural Bond Sites Pattern Spacing and Area Measurement Method. Thestructural bonds are applied with the same method as described above forEx. 1-3 and Comp. Ex. A-B.

Combinations/Examples

-   -   Paragraph A. A disposable absorbent article comprising:        -   a front end region, a middle region, and a back end region;        -   a topsheet;        -   a backsheet; and        -   an absorbent core structure disposed between the topsheet            and backsheet, wherein the absorbent core structure            comprises:        -   a. an upper nonwoven layer comprising polymer fibers and            having a basis weight of from 30 gsm to 65 gsm; wherein the            upper nonwoven layer comprises a first side region, a            laterally opposing second side region, and a first nonwoven            lateral width;        -   b. a lower nonwoven layer comprising polymer fibers and            having a basis weight of from 10 gsm to 40 gsm; wherein the            lower nonwoven layer comprises a first side region, a            laterally opposing second side region, and a nonwoven second            lateral width; and        -   c. an inner core layer having a longitudinal inner core            length, a first inner core layer lateral width, and a second            inner core lateral width; wherein a portion of the inner            core layer is disposed between the upper nonwoven layer and            the lower nonwoven layer;        -   wherein the inner core layer comprises a liquid absorbent            material comprising from 50% to 85% cellulosic fibers, by            weight of the inner core layer, and from 15% to 50%            superabsorbent particles, by weight of the inner core layer;            wherein the absorbent core structure has an average density            of between 0.045 g/cm3 and 0.15 g/cm3;        -   wherein the portion of the inner core layer is contained            within the upper nonwoven layer and the lower nonwoven layer            by sealing a portion of the first side region and the second            side region of the upper nonwoven layer with a portion of            the first side region and the second side region of the            lower nonwoven layer at a lateral perimeter seal, wherein an            adhesive is positioned between the upper nonwoven layer and            the lower nonwoven layer in the perimeter seal;        -   wherein the lateral perimeter seal is positioned in the            middle region and has a longitudinal seal length that is            from 45% to 90% of the longitudinal inner core length.    -   Paragraph B. The disposable absorbent article of Paragraph A,        wherein the first inner core layer lateral width is greater than        at least one of the first nonwoven lateral width and the second        nonwoven lateral width.    -   Paragraph C. The disposable absorbent article of Paragraph A or        B, wherein the second inner core layer lateral width is greater        than at least one of the first nonwoven lateral width and the        second nonwoven lateral width.    -   Paragraph D. The disposable absorbent article of Paragraph A,        wherein the entire inner core layer is disposed between the        upper nonwoven layer and the lower nonwoven layer.    -   Paragraph E. The disposable absorbent article of Paragraph A,        wherein the upper nonwoven layer and the lower nonwoven layer        substantially surrounds the adhesive zone and the inner core        layer; wherein a portion of the inner core layer extends        laterally outboard of the adhesive zone to define an unsealed        portion; wherein the unsealed portion is positioned        longitudinally outboard of the lateral perimeter seal.    -   Paragraph F. The disposable absorbent article of Paragraph E,        wherein the unsealed portion has an unsealed longitudinal length        that is 5% to 30% of the longitudinal inner core length.    -   Paragraph G. The disposable absorbent article of Paragraph E or        F, wherein the unsealed portion is positioned in the back end        region.    -   Paragraph H. The disposable absorbent article of any one of        claims E-G, wherein a second portion of the inner core layer        extends laterally outboard of the adhesive zone to define a        second unsealed region; wherein the second unsealed region is        positioned longitudinally outboard of the perimeter seal.    -   Paragraph I. The disposable absorbent article of any of the        preceding claims, wherein the upper nonwoven layer and the lower        nonwoven layer are further joined by at least one of a front        perimeter seal region and a back perimeter seal region.    -   Paragraph J. The disposable absorbent article of Paragraph I,        wherein the at least one front perimeter seal region and the        back perimeter seal region extend longitudinally outboard from        an inner core layer perimeter a distance of from 3 mm to 30 mm    -   Paragraph K. The disposable absorbent article of any of the        preceding claims, wherein the first nonwoven lateral width and        the second nonwoven lateral width are different.    -   Paragraph L. The disposable absorbent article of any of the        preceding claims, wherein the first nonwoven lateral width and        the second nonwoven lateral width are the same.    -   Paragraph M. The disposable absorbent article of any of the        preceding claims, wherein the absorbent article comprises a        front article edge and a back article edge; wherein the upper        nonwoven layer and the lower nonwoven layer each comprise a        front edge; wherein the front edge of at least one of the upper        nonwoven layer and the lower nonwoven layer is coterminous with        the front article edge.    -   Paragraph N. The disposable absorbent article of Paragraph M,        wherein the upper nonwoven layer and the lower nonwoven layer        each comprise a back edge and the back edge of at least one of        the upper nonwoven layer and the lower nonwoven layer is        coterminous with the back article edge.    -   Paragraph O. The disposable absorbent article of any of the        preceding claims, wherein at least one of the upper nonwoven        layer and the lower nonwoven layer is shaped.    -   Paragraph P. The disposable absorbent article of any of the        preceding claims, further comprising a crimp seal comprising the        topsheet, the backsheet, and at least one of the upper nonwoven        layer and the lower nonwoven layer.    -   Paragraph Q. The disposable absorbent article of any of the        preceding claims, wherein the lateral perimeter seal has a        maximum seal width of from about 1 mm to about 15 mm    -   Paragraph R. The disposable absorbent article of any of the        preceding claims, wherein the inner core layer has a third inner        core layer lateral width, wherein the third inner core layer        lateral width is less than the first inner core layer lateral        width and the second inner core layer lateral width.    -   Paragraph S. The disposable absorbent article of Paragraph R,        wherein the second inner core layer lateral width is greater        than the first inner core layer lateral width and the third        inner core layer lateral width.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A disposable absorbent article comprising: afront end region, a middle region, and a back end region; a topsheet; abacksheet; and an absorbent core structure disposed between the topsheetand backsheet, wherein the absorbent core structure comprises: a. anupper nonwoven layer comprising polymer fibers and having a basis weightof from about 30 gsm to about 65 gsm; wherein the upper nonwoven layercomprises a first side region, a laterally opposing second side region,and a first nonwoven lateral width; b. a lower nonwoven layer comprisingpolymer fibers and having a basis weight of from about 10 gsm to about40 gsm; wherein the lower nonwoven layer comprises a first side region,a laterally opposing second side region, and a nonwoven second lateralwidth; and c. an inner core layer having a longitudinal inner corelength, a first inner core layer lateral width, and a second inner corelateral width; wherein a portion of the inner core layer is disposedbetween the upper nonwoven layer and the lower nonwoven layer; whereinthe inner core layer comprises a liquid absorbent material comprisingfrom about 50% to about 85% cellulosic fibers, by weight of the innercore layer, and from about 15% to about 50% superabsorbent particles, byweight of the inner core layer; wherein the absorbent core structure hasan average density of between about 0.045 g/cm3 and about g/cm3; whereinthe portion of the inner core layer is contained within the uppernonwoven layer and the lower nonwoven layer by sealing a portion of thefirst side region and the second side region of the upper nonwoven layerwith a portion of the first side region and the second side region ofthe lower nonwoven layer at a lateral perimeter seal, wherein anadhesive is positioned between the upper nonwoven layer and the lowernonwoven layer in the perimeter seal; wherein the lateral perimeter sealis positioned in the middle region and has a longitudinal seal lengththat is from about 45% to about 90% of the longitudinal inner corelength.
 2. The disposable absorbent article of claim 1, wherein thefirst inner core layer lateral width is greater than at least one of thefirst nonwoven lateral width and the second nonwoven lateral width. 3.The disposable absorbent article of claim 1, wherein the second innercore layer lateral width is greater than at least one of the firstnonwoven lateral width and the second nonwoven lateral width.
 4. Thedisposable absorbent article of claim 1, wherein the entire inner corelayer is disposed between the upper nonwoven layer and the lowernonwoven layer.
 5. The disposable absorbent article of claim 1, whereinthe upper nonwoven layer and the lower nonwoven layer are further joinedby at least one of a front perimeter seal region and a back perimeterseal region.
 6. The disposable absorbent article of claim 5, wherein theat least one front perimeter seal region and the back perimeter sealregion extend longitudinally outboard from an inner core layer perimetera distance of from about 3 mm to about 30 mm.
 7. The disposableabsorbent article of claim 1, wherein the first nonwoven lateral widthand the second nonwoven lateral width are different.
 8. The disposableabsorbent article of claim 1, wherein the first nonwoven lateral widthand the second nonwoven lateral width are the same.
 9. The disposableabsorbent article of claim 1, wherein the absorbent article comprises afront article edge and a back article edge; wherein the upper nonwovenlayer and the lower nonwoven layer each comprise a front edge; whereinthe front edge of at least one of the upper nonwoven layer and the lowernonwoven layer is coterminous with the front article edge.
 10. Thedisposable absorbent article of claim 9, wherein the upper nonwovenlayer and the lower nonwoven layer each comprise a back edge and theback edge of at least one of the upper nonwoven layer and the lowernonwoven layer is coterminous with the back article edge.
 11. Thedisposable absorbent article of claim 1, wherein at least one of theupper nonwoven layer and the lower nonwoven layer is shaped.
 12. Thedisposable absorbent article of claim 1, further comprising a crimp sealcomprising the topsheet, the backsheet, and at least one of the uppernonwoven layer and the lower nonwoven layer.
 13. The disposableabsorbent article of claim 12, wherein the crimp seal is positioned inat least one of the front end region and the back end region.
 14. Thedisposable absorbent article of claim 12, wherein the crimp seal issubstantially free of the liquid absorbent material.
 15. The disposableabsorbent article of claim 1, wherein the lateral perimeter seal has amaximum seal width of from about 1 mm to about 15 mm.
 16. A disposableabsorbent article comprising: a front end region, a middle region, and aback end region; a topsheet; a backsheet; and an absorbent corestructure disposed between the topsheet and backsheet, wherein theabsorbent core structure comprises: a. an upper nonwoven layercomprising polymer fibers and having a basis weight of from about 30 gsmto about 65 gsm; wherein the upper nonwoven layer comprises a first sideregion and a laterally opposing second side region; b. a lower nonwovenlayer comprising polymer fibers and having a basis weight of from about10 gsm to about 40 gsm; wherein the lower nonwoven layer comprises afirst side region and a laterally opposing second side region; c. aninner core layer comprising a first side edge and a laterally opposingsecond side edge and having a longitudinal inner core length; whereinthe inner core layer is positioned between the upper nonwoven layer andthe lower nonwoven layer; and d. an adhesive zone disposed intermediatea portion of at least one of the upper nonwoven layer and the lowernonwoven layer and the inner core layer; wherein the inner core layercomprises a liquid absorbent material comprising a cellulosic fiber anda superabsorbent particle, and wherein the absorbent core structure hasan average density of between about 0.045 g/cm3 and about 0.15 g/cm3;wherein the upper nonwoven layer and the lower nonwoven layersubstantially surrounds the adhesive zone and the inner core layer;wherein a portion of the adhesive zone extends laterally outboard of thefirst and second side edges of the inner core layer and bonds the uppernonwoven layer to the lower nonwoven layer at a lateral perimeter seal;wherein a portion of the inner core layer extends laterally outboard ofthe adhesive zone to define an unsealed portion; wherein the unsealedportion is positioned longitudinally outboard of the lateral perimeterseal.
 17. The disposable absorbent article of claim 16, wherein thelateral perimeter seal is positioned in the middle region.
 18. Thedisposable absorbent article of claim 16, wherein the unsealed portionhas an unsealed longitudinal length that is about 5% to about 30% of thelongitudinal inner core length.
 19. The disposable absorbent article ofclaim 16, wherein the unsealed portion is positioned in the back endregion.
 20. The disposable absorbent article of claim 16, wherein asecond portion of the shaped inner core layer extends laterally outboardof the adhesive zone to define a second unsealed region; wherein thesecond unsealed region is positioned longitudinally outboard of theperimeter seal.
 21. The disposable absorbent article of claim 16,wherein the inner core layer has a first inner core layer lateral width,a second inner core layer lateral width, and a third inner core layerlateral width disposed therebetween.
 22. The disposable absorbentarticle of claim 21, wherein the third inner core layer lateral width isless than the first inner core layer lateral width and the second innercore layer lateral width.
 23. The disposable absorbent article of claim22, wherein the second inner core layer lateral width is greater thanthe first inner core layer lateral width and the third inner core layerlateral width.
 23. The disposable absorbent article of claim 21, whereinthe adhesive zone has an adhesive zone lateral width, and wherein thefirst inner core layer lateral width and the adhesive zone lateral widthare substantially the same.
 24. The disposable absorbent article ofclaim 21, wherein the adhesive zone has an adhesive zone lateral width,and wherein the adhesive zone lateral width is greater than the firstinner core layer lateral width.